Handheld electromechanical surgical system

ABSTRACT

An adapter assembly includes a switch actuator, an actuation bar, and a latch. The switch actuator is movable between a proximal position, in which the switch actuator actuates a switch, and a distal position. The latch is movable between a first position, in which the latch permits proximal movement of the switch actuator, and a second position, in which the latch prevents proximal movement of the switch actuator. The latch is configured to move from the first position toward the second position in response to the actuation bar moving toward a proximal position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation application of U.S. patentapplication Ser. No. 15/612,542, filed on Jun. 2, 2017, now U.S. Pat.No. 10,426,466, which is a Continuation-in-part application of U.S.patent application Ser. No. 15/096,399, filed on Apr. 12, 2016, now U.S.Pat. No. 10,426,468, which claims the benefit of, and priority to, U.S.Provisional Patent Application No. 62/291,775, filed on Feb. 5, 2016,and U.S. Provisional Patent Application Nos.: 62/151,145; 62/151,171;62/151,183; 62/151,196; 62/151,206; 62/151,224; 62/151,235; 62/151,246;62/151,255; 62/151,261; 62/151,266; and 62/151,273, each of which wasfiled on Apr. 22, 2015, the entire contents of each of which areincorporated herein by reference.

BACKGROUND 1. Technical Field

The present disclosure relates to surgical devices. More specifically,the present disclosure relates to handheld electromechanical surgicalsystems for performing surgical procedures.

2. Background of Related Art

One type of surgical device is a linear clamping, cutting and staplingdevice. Such a device may be employed in a surgical procedure to resecta cancerous or anomalous tissue from a gastro-intestinal tract.Conventional linear clamping, cutting and stapling instruments include apistol grip-styled structure having an elongated shaft and distalportion. The distal portion includes a pair of scissors-styled grippingelements, which clamp the open ends of the colon closed. In this device,one of the two scissors-styled gripping elements, such as the anvilportion, moves or pivots relative to the overall structure, whereas theother gripping element remains fixed relative to the overall structure.The actuation of this scissoring device (the pivoting of the anvilportion) is controlled by a grip trigger maintained in the handle.

In addition to the scissoring device, the distal portion also includes astapling mechanism. The fixed gripping element of the scissoringmechanism includes a staple cartridge receiving region and a mechanismfor driving the staples up through the clamped end of the tissue againstthe anvil portion, thereby sealing the previously opened end. Thescissoring elements may be integrally formed with the shaft or may bedetachable such that various scissoring and stapling elements may beinterchangeable.

A number of surgical device manufacturers have developed product lineswith proprietary powered drive systems for operating and/or manipulatingthe surgical device. In many instances the surgical devices include apowered handle assembly, which is reusable, and a disposable endeffector or the like that is selectively connected to the powered handleassembly prior to use and then disconnected from the end effectorfollowing use in order to be disposed of or in some instances sterilizedfor re-use.

The use of powered electro and endomechanical surgical staplers,including intelligent battery power, has grown tremendously over thepast few decades. Advanced technology and informatics within theseintelligent battery-powered stapling devices provide the ability togather clinical data and drive design improvements to ultimately improvepatient outcomes. Accordingly, a need exists to evaluate conditions thataffect staple formation with the intention of building a moreintelligent stapling algorithm.

SUMMARY

In one aspect of the present disclosure, an adapter assembly isprovided, which includes an elongate body, a switch actuator disposedwithin the elongate body, an actuator bar disposed within the elongatebody, and a latch. The elongate body includes a proximal portionconfigured to couple to a handle assembly and a distal portionconfigured to couple to a surgical loading unit. The switch actuator ismovable between a proximal position, in which the switch actuatoractuates a switch, and a distal position. The actuation bar is movablebetween a proximal position and a distal position. The latch isassociated with the switch actuator and the actuation bar and is movablebetween a first position, in which the latch permits proximal movementof the switch actuator, and a second position, in which the latchprevents proximal movement of the switch actuator. The latch isconfigured to move from the first position toward the second position inresponse to the actuation bar moving toward the proximal position.

In some embodiments, the adapter assembly may further include a distallink disposed distally of the switch actuator, and a biasing memberdisposed between the switch actuator and the distal link. Proximalmovement of the distal link may compress the biasing member between theswitch actuator and the distal link when the latch is in the secondposition. The actuation bar may be configured to move the latch towardthe first position to unlock the switch actuator from the latch duringmovement of the actuation bar toward the distal position, such that thebiasing member moves the switch actuator toward the proximal position toactuate the switch.

It is contemplated that the latch may include a projection extendingfrom a distal portion thereof, and the actuation bar may include a tabextending from a distal portion thereof. The tab of the actuation barmay be configured to contact the projection of the latch upon theactuation bar moving toward the distal position.

It is envisioned that the latch may have a proximal portion defining agroove therein. A distal portion of the switch actuator may have a tabextending therefrom dimensioned for receipt in the groove of theproximal portion of the latch.

In some embodiments, the latch may be resiliently biased toward thesecond position.

It is contemplated that the latch may include a proximal portionoperably associated with the switch actuator, and a distal portionoperably associated with the actuation bar.

It is envisioned that the proximal portion of the latch may have amating feature, and a distal portion of the switch actuator may have amating feature. The mating feature of the switch actuator may beconfigured to detachably matingly engage with the mating feature of thelatch when the latch is in the second position and the switch actuatoris in the distal position.

In some embodiments, a distal portion of the latch may include aprojection, and a distal portion of the actuation bar may include aprojection such that the projection of the distal portion of theactuation bar contacts the projection of the distal portion of the latchduring movement of the actuation bar toward the distal position toeffect pivoting of the latch toward the first position.

It is contemplated that movement of the actuation bar toward the distalposition may pivot the latch toward the first position to release theswitch actuator from the latch.

It is envisioned that the adapter assembly may further include a biasingmember coupled to the latch to resiliently bias the latch toward thesecond position.

In some embodiments, the adapter assembly may further include a releaselever fixed to a proximal portion of the actuation bar to provide manualactuation of the actuation bar.

It is contemplated that both the switch actuator and the actuation barmay be resiliently biased toward their distal positions.

In another aspect of the present disclosure, an adapter assembly isprovided, which includes an elongate body, a switch actuator disposedwithin the elongate body, a distal link, an actuation bar disposedwithin the elongate body, and a latch. The elongate body includes aproximal portion configured to couple to a handle assembly and a distalportion configured to couple to a surgical loading unit. The switchactuator is movable between a proximal position, in which the switchactuator actuates a switch, and a distal position. The distal link isdisposed distally of the switch actuator and is operably coupled to theswitch actuator. The actuation bar is movable between a proximalposition and a distal position. The latch is associated with the switchactuator and the actuation bar and is movable between a first position,in which the latch permits proximal movement of the switch actuator, anda second position, in which the latch prevents proximal movement of theswitch actuator. The latch is configured to move from the secondposition toward the first position in response to the actuation barmoving toward the distal position to allow the switch actuator to moverelative to the distal link and toward the proximal position to actuatethe switch.

In some embodiments, the adapter assembly may further include a biasingmember disposed between the switch actuator and the distal link.Proximal movement of the distal link may compress the biasing memberbetween the switch actuator and the distal link when the latch is in thesecond position. The actuation bar may be configured to move the latchtoward the first position to unlock the switch actuator from the latchduring movement of the actuation bar toward the distal position, suchthat the biasing member moves the switch actuator relative to the distallink and toward the proximal position to actuate the switch.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein withreference to the accompanying drawings, wherein:

FIG. 1 is a perspective view of a handheld surgical device and adapterassembly, in accordance with an embodiment of the present disclosure,illustrating a connection thereof with an end effector;

FIG. 2 is a perspective view of the handheld surgical device of FIG. 1;

FIG. 3 is a front perspective view, with parts separated, of thehandheld surgical device of FIGS. 1 and 2;

FIG. 4 is a rear perspective view, with parts separated, of the handheldsurgical device of FIGS. 1 and 2;

FIG. 5 is a perspective view illustrating insertion of a power-pack intoan outer shell housing of the handheld surgical device;

FIG. 6 is a perspective view illustrating the power-pack nested into theouter shell housing of the handheld surgical device;

FIG. 7 is a side elevational view of the outer shell housing of thehandheld surgical device;

FIG. 8 is a bottom perspective view of the outer shell housing of thehandheld surgical device, and an insertion guide thereof;

FIG. 9 is an enlarged, bottom perspective view of the outer shellhousing of the handheld surgical device with the insertion guideseparated therefrom;

FIG. 10 is a first perspective view of the insertion guide;

FIG. 11 is a second perspective view of the insertion guide;

FIG. 12 is a front, perspective view of the power-pack with an innerrear housing separated therefrom;

FIG. 13 is a rear, perspective view of the power-pack with the innerrear housing removed therefrom;

FIG. 14 is a perspective view of a power-pack core assembly of thepower-pack;

FIG. 15 is a front, perspective view of a motor assembly and a controlassembly of the power-pack core assembly of FIG. 14;

FIG. 16 is a rear, perspective view, with parts separated, of the motorassembly and the control assembly of FIG. 15;

FIG. 17 is a longitudinal, cross-sectional view of the handheld surgicaldevice of FIG. 2;

FIG. 18 is an enlarged view of the indicated area of detail of FIG. 17;

FIG. 19 is a cross-sectional view of the handheld surgical device astaken through 19-19 of FIG. 17;

FIG. 20 is a front, perspective view of the adapter assembly of FIG. 1;

FIG. 21 is a rear, perspective view of the adapter assembly of FIGS. 1and 20;

FIG. 22 is a perspective view illustrating a connection of the adapterassembly and the handheld surgical device;

FIG. 23 is a top, plan view of the adapter assembly of FIGS. 1 and20-22;

FIG. 24 is a side, elevational view of the adapter assembly of FIGS. 1and 20-23;

FIG. 25 is a perspective view, with parts separated, of the adapterassembly of FIGS. 1 and 20-24;

FIG. 26 is a rear, perspective view of the adapter assembly of FIGS. 1and 20-25, with most parts thereof separated;

FIG. 27 is a perspective view of an articulation assembly of the adapterassembly of FIGS. 1 and 20-26;

FIG. 28 is an enlarged, perspective view, with parts separated, of thearticulation assembly of FIG. 27;

FIG. 29 is a perspective view of the articulation assembly of FIG. 27,shown in a first orientation;

FIG. 30 is a perspective view of the articulation assembly of FIG. 27,shown in a second orientation;

FIG. 31 is a cross-sectional view of the articulation assembly of FIG.29;

FIG. 32 is a perspective view of an electrical assembly of the adapterassembly of FIGS. 1 and 20-26;

FIG. 33 is a perspective view of the electrical assembly shown supportedon a proximal inner housing assembly;

FIG. 34 is a perspective view of a slip ring cannula or sleeve of theadapter assembly of FIGS. 1 and 20-26;

FIG. 35 is a cross-sectional view as taken along section line 35-35 ofFIG. 33;

FIG. 36 is a longitudinal, cross-sectional view of the adapter assemblyof FIGS. 1 and 20-26;

FIG. 37 is an enlarged view of the indicated area of detail of FIG. 21;

FIG. 38 is a rear, perspective view of the inner housing assembly of theadapter assembly of FIGS. 1 and 20-26, with an outer knob housinghalf-section and a proximal cap removed therefrom;

FIG. 39 is a rear, perspective view of the inner housing assembly of theadapter assembly of FIGS. 1 and 20-26, with the outer knob housing, theproximal cap and a bushing plate removed therefrom;

FIG. 40 is a rear, perspective view of the inner housing assembly of theadapter assembly of FIGS. 1 and 20-26, with the outer knob housing, theproximal cap, the bushing plate and an inner housing removed therefrom;

FIG. 41 is an enlarged view of the indicated area of detail of FIG. 36;

FIG. 42 is an enlarged view of the indicated area of detail of FIG. 36,illustrating a lock button being actuated in a proximal direction;

FIG. 43 is a cross-sectional view as taken along section line 43-43 ofFIG. 37;

FIG. 44 is a longitudinal, cross-sectional view of the inner and outerknob housing of the adapter assembly, illustrating actuation of thearticulation assembly in a distal direction;

FIG. 45 is a cross-sectional view as taken along section line 45-45 ofFIG. 44;

FIG. 46 is a cross-sectional view as taken along section line 46-46 ofFIG. 44;

FIG. 47 is a cross-sectional view as taken along section line 47-47 ofFIG. 44;

FIG. 48 is a cutaway view of a distal portion of the adapter assemblyshown of FIGS. 1 and 20-26, without a loading unit engaged therewith;

FIG. 49 is a perspective view of an annular member of the adapterassembly of FIGS. 1 and 20-26;

FIG. 50 is a perspective view of the annular member shown in FIG. 49electrically connected to a switch of the adapter assembly of FIGS. 1and 20-26;

FIG. 51 is an enlarged view of the distal portion of the adapterassembly of FIGS. 1 and 20-26, including the annular member and theswitch assembled therein;

FIG. 52 is another cutaway view of the distal portion of the adapterassembly of FIGS. 1 and 20-26, without a loading unit engaged therewith;

FIG. 53 is a perspective view of the loading unit of FIG. 1;

FIG. 54 is a perspective view, with parts separated, of the loading unitof FIGS. 1 and 53;

FIGS. 55 and 56 are alternate perspective views of an inner housing ofthe loading unit shown in FIGS. 1 and 53-54;

FIGS. 57 and 58 are alternate cutaway views of the loading unit shown inFIGS. 1 and 53-54, with the inner and outer housings assembled;

FIGS. 59 and 60 are alternate cutaway views of an outer housing of theloading unit shown in FIGS. 1 and 53-54;

FIGS. 61 and 62 are alternate cutaway views of the distal portion of theadapter assembly of FIGS. 1 and 20-26 engaged with the loading unit,illustrating the annular member in a first orientation and a sensor linkin a non-locking configuration;

FIGS. 63 and 64 are alternate cutaway views of the distal portion of theadapter assembly of FIGS. 1 and 20-26 engaged with the loading unit,illustrating the annular member in a second orientation and the sensorlink in a locking configuration;

FIG. 65 is an enlarged cutaway view of the distal portion of the adapterassembly of FIGS. 1 and 20-26;

FIG. 66 is a cutaway view of the loading unit of FIGS. 1 and 53-54inserted into the annular member shown in FIG. 49;

FIG. 67 is a cross-sectional view of the loading unit of FIGS. 1 and53-54, taken along line 67-67 of FIG. 66;

FIG. 68 is a cross-sectional view of the loading unit of FIGS. 1 and53-54, taken along line 68-68 of FIG. 66;

FIGS. 69A-69D are perspective views of various other loading unitsconfigured for use with the handheld surgical device of FIG. 1;

FIG. 70 is a schematic diagram of the circuit board of the power-pack ofthe handheld surgical device of FIG. 1;

FIG. 71 is a block diagram of a simplified system hardware of thepower-pack of the handheld surgical device of FIG. 1;

FIG. 72 is a flow diagram of a method for controlling various modes ofthe power-pack of the handheld surgical device of FIG. 1;

FIG. 73 is a flow diagram of a method of initializing the power-pack ofthe handheld surgical device of FIG. 1;

FIG. 74 is a flow diagram of a portion of the method of initializing ofFIG. 73;

FIG. 75 is a flow diagram of another portion of the method ofinitializing of FIG. 73;

FIG. 76 is a flow diagram of yet another portion of the method ofinitializing of FIG. 73;

FIG. 77 is a flow diagram of a wire testing method of the method ofinitializing of FIG. 73;

FIG. 78 is a flow diagram of a method of validating components of thehandheld surgical device of FIG. 1;

FIG. 79 is a flow diagram of a portion of the method of validatingcomponents of FIG. 78;

FIG. 80 is a flow diagram of a method of calibrating components of thehandheld surgical device of FIG. 1;

FIG. 81 is a flow diagram of another method of calibrating of thehandheld surgical device of FIG. 1;

FIG. 82 is a block diagram of the operation module of the systemhardware of FIG. 71;

FIG. 83 is a side view of another embodiment of an adapter assembly forinterconnecting a handheld surgical device and a loading unit of thepresent disclosure;

FIG. 84 is a perspective view, with outer housings removed, of theadapter assembly of FIG. 83;

FIG. 85 is an enlarged view, with an outer housing removed, of a distalportion of the adapter assembly illustrating a switch actuationmechanism thereof in a pre-loaded state;

FIG. 86 is a side, perspective view of the adapter assembly of FIG. 85illustrating a loading unit inserted within the elongate body of theadapter assembly;

FIG. 87 is a side, perspective view of the adapter assembly and theloading unit of FIG. 86 illustrating the switch actuation mechanism in afirst loaded state; and

FIG. 88 is a side, perspective view of the adapter assembly and theloading unit of FIG. 86 illustrating the switch actuation mechanism in asecond loaded state.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical devices, and adapterassemblies for surgical devices and/or handle assemblies are describedin detail with reference to the drawings, in which like referencenumerals designate identical or corresponding elements in each of theseveral views. As used herein the term “distal” refers to that portionof the adapter assembly or surgical device, or component thereof,farther from the user, while the term “proximal” refers to that portionof the adapter assembly or surgical device, or component thereof, closerto the user.

A surgical device, in accordance with an embodiment of the presentdisclosure, is generally designated as 100, and is in the form of apowered hand held electromechanical instrument configured for selectiveattachment thereto of a plurality of different end effectors that areeach configured for actuation and manipulation by the powered hand heldelectromechanical surgical instrument. In addition to enabling poweredactuation and manipulation, surgical device 100 further incorporatesvarious safety and control features that help ensure proper, safe, andeffective use thereof.

As illustrated in FIG. 1, surgical device is configured for selectiveconnection with an adapter 200, and, in turn, adapter 200 is configuredfor selective connection with end effectors or single use loading units(“SULU's”) 400. Although described with respect to adapter 200 and SULU400, different adapters configured for use with different end effectorsand/or different end effectors configured for use with adapter 200 arealso capable of being used with surgical device 100. Suitable endeffectors configured for use with adapter 200 and/or other adaptersusable with surgical device 100 include end effectors configured forperforming endoscopic gastro-intestinal anastomosis (EGIA) procedures,e.g., SULU 400 and multi-use loading unit (“MULU”) 900B (FIG. 69B1), endeffectors configured to perform end-to-end anastomosis (EEA) procedures,e.g., loading unit 900A (FIG. 69A), a transverse stapling loading units,e.g., loading unit 900C (FIG. 69C), and curved loading units, e.g.,loading unit 900D (FIG. 69D).

As illustrated in FIGS. 1-11, surgical device 100 includes a power-pack101, and an outer shell housing 10 configured to selectively receive andsealingly encase power-pack 101 to establish a sterile barrier aboutpower-pack 101. Outer shell housing 10 includes a distal half-section 10a and a proximal half-section 10 b pivotably connected to distalhalf-section 10 a by a hinge 16 located along an upper edge of distalhalf-section 10 a and proximal half-section 10 b. When joined, distaland proximal half-sections 10 a, 10 b define a shell cavity 10 c thereinin which power-pack 101 is selectively situated.

Distal and proximal half-sections 10 a, 10 b are divided along a planethat traverses a longitudinal axis “X” of adapter 200.

Each of distal and proximal half-sections 10 a, 10 b includes arespective upper shell portion 12 a, 12 b, and a respective lower shellportion 14 a, 14 b. Lower shell portions 12 a, 12 b define a snapclosure feature 18 for selectively securing lower shell portions 12 a,12 b to one another and for maintaining outer shell housing 10 in aclosed condition.

Distal half-section 10 a of outer shell housing 10 defines a connectingportion 20 configured to accept a corresponding drive coupling assembly210 of adapter 200. Specifically, distal half-section 10 a of outershell housing 10 has a recess 20 that receives a portion of drivecoupling assembly 210 of adapter 200 when adapter 200 is mated tosurgical device 100.

Connecting portion 20 of distal half-section 10 a defines a pair ofaxially extending guide rails 20 a, 20 b projecting radially inward frominner side surfaces thereof. Guide rails 20 a, 20 b assist inrotationally orienting adapter 200 relative to surgical device 100 whenadapter 200 is mated to surgical device 100.

Connecting portion 20 of distal half-section 10 a defines threeapertures 22 a, 22 b, 22 c formed in a distally facing surface thereofand which are arranged in a common plane or line with one another.Connecting portion 20 of distal half-section 10 a also defines anelongate slot 24 (to contain connector 66, see FIG. 3) also formed inthe distally facing surface thereof.

Connecting portion 20 of distal half-section 10 a further defines afemale connecting feature 26 (see FIG. 2) formed in a surface thereof.Female connecting feature 26 selectively engages with a male connectingfeature of adapter 200, as will be described in greater detail below.

Distal half-section 10 a of outer shell housing 10 supports a distalfacing toggle control button 30. Toggle control button 30 is capable ofbeing actuated in a left, right, up and down direction upon applicationof a corresponding force thereto or a depressive force thereto.

Distal half-section 10 a of outer shell housing 10 supports a right-sidepair of control buttons 32 a, 32 b; and a left-side pair of controlbutton 34 a, 34 b. Right-side control buttons 32 a, 32 b and left-sidecontrol buttons 34 a, 34 b are capable of being actuated uponapplication of a corresponding force thereto or a depressive forcethereto.

Proximal half-section 10 b of outer shell housing 10 supports aright-side control button 36 a and a left-side control button 36 b.Right-side control button 36 a and left-side control button 36 b arecapable of being actuated upon application of a corresponding forcethereto or a depressive force thereto.

Distal half-section 10 a and proximal half-section 10 b of outer shellhousing 10 are fabricated from a polycarbonate or similar polymer, andare clear or transparent or may be overmolded.

With reference to FIGS. 5-11, surgical device 100 includes an insertionguide 50 that is configured and shaped to seat on and entirely surrounda distal facing edge 10 d (FIGS. 3 and 9) of proximal half-section 10 b.Insertion guide 50 includes a body portion 52 having a substantiallyU-shaped transverse cross-sectional profile, and a stand-off 54extending from a bottom of body portion 52. Stand-off 54 is configuredto engage snap closure feature 18 of each of lower shell portions 12 a,12 b of respective distal and proximal half-sections 10 a, 10 b of outershell housing 10.

In use, when body portion 52 of insertion guide 50 is seated on distalfacing edge 10 d of proximal half-section 10 b, snap closure feature 18of lower shell portion 12 a of distal half-section 10 a engages a firstend of stand-off 54, and snap closure feature 18 of lower shell portion12 b of proximal half-section 10 b engages a first end of stand-off 54.

With reference to FIGS. 2-4, outer shell housing 10 includes a sterilebarrier plate assembly 60 selectively supported in distal half-section10 a. Specifically, sterile barrier plate assembly 60 is disposed behindconnecting portion 20 of distal half-section 10 a and within shellcavity 10 c of outer shell housing 10. Plate assembly 60 includes aplate 62 rotatably supporting three coupling shafts 64 a, 64 b, 64 c.Each coupling shaft 64 a, 64 b, 64 c extends from opposed sides of plate62 and has a tri-lobe transverse cross-sectional profile. Each couplingshaft 64 a, 64 b, 64 c extends through a respective aperture 22 a, 22 b,22 c of connecting portion 20 of distal half-section 10 a when sterilebarrier plate assembly 60 is disposed within shell cavity 10 c of outershell housing 10.

Plate assembly 60 further includes an electrical pass-through connector66 supported on plate 62. Pass-through connector 66 extends from opposedsides of plate 62. Each coupling shaft 64 a, 64 b, 64 c extends throughaperture 24 of connecting portion 20 of distal half-section 10 a whensterile barrier plate assembly 60 is disposed within shell cavity 10 cof outer shell housing 10. Pass-through connector 66 defines a pluralityof contact paths each including an electrical conduit for extending anelectrical connection across plate 62. The various communicationsrelayed across pass-through connector 66 are described in detail belowwith respect to FIGS. 70-82.

When plate assembly 60 is disposed within shell cavity 10 c of outershell housing 10, distal ends of coupling shaft 64 a, 64 b, 64 c and adistal end of pass-through connector 66 are disposed or situated withinconnecting portion 20 of distal half-section 10 a of outer shell housing10, and electrically and/or mechanically engage respective correspondingfeatures of adapter 200, as will be described in greater detail below.

In operation, with a new and/or sterile outer shell housing 10 in anopen configuration (i.e., distal half-section 10 a separated fromproximal half-section 10 b, about hinge 16), and with insertion guide 50in place against the distal edge of proximal half-section 10 b of outershell housing 10, power-pack 101 is inserted into shell cavity 10 c ofouter shell housing 10. With power-pack 101 inserted into shell cavity10 c of outer shell housing 10, insertion guide 50 is removed fromproximal half-section 10 b and distal half-section 10 a is pivoted,about hinge 16, to a closed configuration for outer shell housing 10. Inthe closed configuration, snap closure feature 18 of lower shell portion12 a of distal half-section 10 a engages snap closure feature 18 oflower shell portion 12 b of proximal half-section 10 b.

In operation, following a surgical procedure, snap closure feature 18 oflower shell portion 12 a of distal half-section 10 a is disengaged fromsnap closure feature 18 of lower shell portion 12 b of proximalhalf-section 10 b, and distal half-section 10 a is pivoted, about hinge16, away from proximal half-section 10 b to open outer shell housing 10.With outer shell housing 10 open, power-pack 101 is removed from shellcavity 10 c of outer shell housing 10 (specifically from proximalhalf-section 10 b of outer shell housing 10), and outer shell housing 10is discarded. Power-pack 101 is then disinfected and cleaned. Power-pack101 is not to be submerged or sterilized.

Outer shell housing 10, in addition to aseptically sealing power-pack101 when engaged thereabout, providing an operational interface forenabling operation of surgical device 100 from the exterior of outershell housing 10, and including electrical and mechanical pass-throughfeatures for transmitting control and drive signals between power-pack101 and the other components of surgical device 100, further includes amemory chip, e.g., a 1-wire chip, embedded therein. The memory chipincludes a memory that stores a unique ID associated with outer shellhousing 10 and is capable of being updated to mark outer shell housing10 as “used.” The unique ID of outer shell housing 10 allows forexclusive pairing of outer shell housing 10 with a power-pack 101, whilethe ability to mark outer shell housing 10 as “used” inhibits reuse ofouter shell housing 10, even with the same power-pack 101. Electricalcontacts associated with the outer shell housing 10 form part of a1-wire bus 171 (FIG. 70), or other suitable communication channel, thatenables communication between power-pack 101 and the 1-wire chip ofouter shell housing 10. These features will be described in greaterdetail below with reference to FIGS. 70-82. The 1-wire chip of outershell housing 10, for example, may be disposed on or within plateassembly 60 thus enabling access thereto via one of the contact pathsdefined via pass-through connector 66. Although other locations and/orelectrical couplings for enabling communication between the 1-wire chipof outer shell housing 10 and power-pack 101 are also contemplated.

Referring to FIGS. 3-6 and FIGS. 12-19, power-pack 101 includes an innerhandle housing 110 having a lower housing portion 104 and an upperhousing portion 108 extending from and/or supported on lower housingportion 104. Lower housing portion 104 and upper housing portion 108 areseparated into a distal half-section 110 a and a proximal half-section110 b connectable to distal half-section 110 a by a plurality offasteners. When joined, distal and proximal half-sections 110 a, 110 bdefine an inner handle housing 110 having an inner housing cavity 110 ctherein in which a power-pack core assembly 106 is situated.

Power-pack core assembly 106 is configured to control the variousoperations of surgical device 100, as will be set forth in additionaldetail below.

Distal half-section 110 a of inner handle housing 110 defines a distalopening 111 a therein which is configured and adapted to support acontrol plate 160 of power-pack core assembly 106. Control plate 160 ofpower-pack 101 abuts against a rear surface of plate 62 of sterilebarrier plate assembly 60 of outer shell housing 10 when power-pack 101is disposed within outer shell housing 10.

With reference to FIG. 12, distal half-section 110 a of inner handlehousing 110 supports a distal toggle control interface 130 that is inoperative registration with distal toggle control button 30 of outershell housing 10. In use, when power-pack 101 is disposed within outershell housing 10, actuation of toggle control button 30 exerts a forceon toggle control interface 130.

Distal half-section 110 a of inner handle housing 110 also supports aright-side pair of control interfaces 132 a, 132 b, and a left-side pairof control interfaces 134 a, 134 b. In use, when power-pack 101 isdisposed within outer shell housing 10, actuation of one of theright-side pair of control buttons 32 a, 32 b or the left-side pair ofcontrol button 34 a, 34 b of distal half-section 10 a of outer shellhousing 10 exerts a force on a respective one of the right-side pair ofcontrol interfaces 132 a, 132 b or the left-side pair of controlinterfaces 134 a, 134 b of distal half-section 110 a of inner handlehousing 110.

In use, right-side pair of control interfaces 132 a, 132 b or theleft-side pair of control interfaces 134 a, 134 b of distal half-section110 a of inner handle housing 110 will be deactivate or fail to functionunless outer shell housing 10 has been validated.

Proximal half-section 110 b of inner handle housing 110 defines aright-side control aperture 136 a and a left-side control aperture 136b. In use, when power-pack 101 is disposed within outer shell housing10, actuation of one of the right-side control button 36 a or theleft-side control button 36 b of proximal half-section 10 b of outershell housing 10 extends the right-side control button 36 a or theleft-side control button 36 b into and across the right-side controlaperture 136 a or the left-side control aperture 136 b of the proximalhalf-section 110 b of inner handle housing 110.

With reference to FIGS. 12-19, inner handle housing 110 provides ahousing in which power-pack core assembly 106 is situated. Power-packcore assembly 106 includes a rechargeable battery 144 configured tosupply power to any of the electrical components of surgical device 100,a battery circuit board 140, and a controller circuit board 142.Controller circuit board 142 includes a motor controller circuit board142 a, a main controller circuit board 142 b, and a first ribbon cable142 c interconnecting motor controller circuit board 142 a and maincontroller circuit board 142 b. The motor controller circuit board 142 ais communicatively coupled with the battery circuit board 140 enablingcommunication therebetween and between the battery circuit board 140 andthe main controller circuit board 142 b.

Power-pack core assembly 106 further includes a display screen 146supported on main controller circuit board 142 b. Display screen 146 isvisible through a clear or transparent window 110 d (see FIGS. 12 and17) provided in proximal half-section 110 b of inner handle housing 110.It is contemplated that at least a portion of inner handle housing 110may be fabricated from a transparent rigid plastic or the like. It isfurther contemplated that outer shell housing 10 may either include awindow formed therein (in visual registration with display screen 146and with window 110 d of proximal half-section 110 b of inner handlehousing 110, and/or outer shell housing 10 may be fabricated from atransparent rigid plastic or the like.

Power-pack core assembly 106 further includes a first motor 152, asecond motor 154, and a third motor 156 each electrically connected tocontroller circuit board 142 and battery 144. Motors 152, 154, 156 aredisposed between motor controller circuit board 142 a and maincontroller circuit board 142 b. Each motor 152, 154, 156 includes arespective motor shaft 152 a, 154 a, 156 a extending therefrom. Eachmotor shaft 152 a, 154 a, 156 a has a tri-lobe transversecross-sectional profile for transmitting rotative forces or torque. Asan alternative to motors 152, 154, 156, it is envisioned that more orfewer motors be provided or that one or more other drive components beutilized, e.g., a solenoid, and controlled by appropriate controllers.Manual drive components are also contemplated.

Each motor 152, 154, 156 is controlled by a respective motor controller“MC0,” MC1,” “MC2.” Motor controllers “MC0,” MC1,” “MC2” are disposed onthe motor controller circuit board 142 a. The motor controllers aredisposed on motor controller circuit board 142 a and are, for example,A3930/31K motor drivers from Allegro Microsystems, Inc. The A3930/31Kmotor drivers are designed to control a 3-phase brushless DC (BLDC)motor with N-channel external power MOSFETs, such as the motors 152,154, 156. Each of the motor controllers is coupled to a main controlleror master chip 157 disposed on the main controller circuit board 142 bvia first ribbon cable 142 c which connects the motor controller circuitboard 142 a with the main controller circuit board 142 b. The maincontroller 157 communicates with motor controllers “MC0,” MC1,” “MC2”through a field-programmable gate array (FPGA) 162, which providescontrol logic signals (e.g., coast, brake, etc.). The control logic ofmotor controllers “MC0,” MC1,” “MC2” then outputs correspondingenergization signals to respective motor 152, 154, 156 usingfixed-frequency pulse width modulation (PWM). The main controller 157 isalso coupled to memory 165, which is also disposed on the maincontroller circuit board 142 b. The main controller 157 is, for example,an ARM Cortex M4 processor from Freescale Semiconductor, Inc, whichincludes 1024 kilobytes of internal flash memory.

Each motor 152, 154, 156 is supported on a motor bracket 148 such thatmotor shaft 152 a, 154 a, 156 a are rotatably disposed within respectiveapertures of motor bracket 148. As illustrated in FIGS. 16 and 19, motorbracket 148 rotatably supports three rotatable drive connector sleeves152 b, 154 b, 156 b that are keyed to respective motor shafts 152 a, 154a, 156 a of motors 152, 154, 156. Drive connector sleeves 152 b, 154 b,156 b non-rotatably receive proximal ends of respective coupling shaft64 a, 64 b, 64 c of plate assembly 60 of outer shell housing 10, whenpower-pack 101 is disposed within outer shell housing 10. Driveconnector sleeves 152 b, 154 b, 156 b are each spring biased away fromrespective motors 152, 154, 156.

Rotation of motor shafts 152 a, 154 a, 156 a by respective motors 152,154, 156 function to drive shafts and/or gear components of adapter 200in order to perform the various operations of surgical device 100. Inparticular, motors 152, 154, 156 of power-pack core assembly 106 areconfigured to drive shafts and/or gear components of adapter 200 inorder to selectively move tool assembly 404 of SULU 400 relative toproximal body portion 402 of SULU 400, to rotate SULU 400 about alongitudinal axis “X,” to move cartridge assembly 408 relative to anvilassembly 406 of SULU 400, and/or to fire staples from within cartridgeassembly 408 of SULU 400.

Motor bracket 148 also supports an electrical adapter interfacereceptacle 149. Electrical receptacle 149 is in electrical connectionwith main controller circuit board 142 b by a second ribbon cable 142 d.Electrical receptacle 149 defines a plurality of electrical slots forreceiving respective electrical contacts or blades extending frompass-through connector 66 of plate assembly 60 of outer shell housing10.

In use, when adapter 200 is mated to surgical device 100, each ofcoupling shaft 64 a, 64 b, 64 c of plate assembly 60 of outer shellhousing 10 of surgical device 100 couples with a corresponding rotatableconnector sleeves 218, 220, 222 of adapter 200 (see FIG. 22). In thisregard, the interface between corresponding first coupling shaft 64 aand first connector sleeve 218, the interface between correspondingsecond coupling shaft 64 b and second connector sleeve 220, and theinterface between corresponding third coupling shaft 64 c and thirdconnector sleeve 222 are keyed such that rotation of each of couplingshafts 64 a, 64 b, 64 c of surgical device 100 causes a correspondingrotation of the corresponding connector sleeve 218, 220, 222 of adapter200. The identification, verification, and other communications betweenpower-pack 101 and adapter 200 upon engagement therebetween are detailedbelow with respect to FIGS. 70-82.

The mating of coupling shafts 64 a, 64 b, 64 c of surgical device 100with connector sleeves 218, 220, 222 of adapter 200 allows rotationalforces to be independently transmitted via each of the three respectiveconnector interfaces. The coupling shafts 64 a, 64 b, 64 c of surgicaldevice 100 are configured to be independently rotated by respectivemotors 152, 154, 156.

Since each of coupling shafts 64 a, 64 b, 64 c of surgical device 100has a keyed and/or substantially non-rotatable interface with respectiveconnector sleeves 218, 220, 222 of adapter 200, when adapter 200 iscoupled to surgical device 100, rotational force(s) are selectivelytransferred from motors 152, 154, 156 of surgical device 100 to adapter200.

The selective rotation of coupling shaft(s) 64 a, 64 b, 64 c of surgicaldevice 100 allows surgical device 100 to selectively actuate differentfunctions of SULU 400. As will be discussed in greater detail below,selective and independent rotation of first coupling shaft 64 a ofsurgical device 100 corresponds to the selective and independent openingand closing of tool assembly 404 of SULU 400, and driving of astapling/cutting component of tool assembly 404 of SULU 400. Also, theselective and independent rotation of second coupling shaft 64 b ofsurgical device 100 corresponds to the selective and independentarticulation of tool assembly 404 of SULU 400 transverse to longitudinalaxis “X” (see FIG. 21). Additionally, the selective and independentrotation of third coupling shaft 64 c of surgical device 100 correspondsto the selective and independent rotation of SULU 400 about longitudinalaxis “X” (see FIG. 21) relative to surgical device 100.

With reference to FIGS. 12-19, power-pack core assembly 106 furtherincludes a switch assembly 170 supported within distal half-section 110a of inner handle housing 110, at a location beneath and in registrationwith toggle control interface 130, the right-side pair of controlinterfaces 132 a, 132 b, and the left-side pair of control interfaces134 a, 134 b. Switch assembly 170 includes a first set of fourpush-button switches 172 a-172 d arranged around stem 30 a of togglecontrol button 30 of outer shell housing 10 when power-pack 101 isdisposed within outer shell housing 10. Switch assembly 170 alsoincludes a second pair of push-button switches 174 a, 174 b disposedbeneath right-side pair of control interfaces 132 a, 132 b of distalhalf-section 110 a of inner handle housing 110 when power-pack 101 isdisposed within outer shell housing 10. Switch assembly 170 furtherincludes a third pair of push-button switches 176 a, 176 b disposedbeneath left-side pair of control interfaces 134 a, 134 b of distalhalf-section 110 a of inner handle housing 110 when power-pack 101 isdisposed within outer shell housing 10.

Power-pack core assembly 106 includes a single right-side push-buttonswitch 178 a disposed beneath right-side control aperture 136 a ofproximal half-section 110 b of inner handle housing 110, and a singleleft-side push-button switch 178 b disposed beneath left-side controlaperture 136 b of proximal half-section 110 b of inner handle housing110. Push-button switches 178 a, 178 b are supported on controllercircuit board 142. Push-button switches 178 a, 178 b are disposedbeneath right-side control button 36 a and left-side control button 36 bof proximal half-section 10 b of outer shell housing 10 when power-pack101 is disposed within outer shell housing 10. Actuation of right orleft-side control button 36 a, 36 b actuates the respective right orleft safety switches or keys 178 a, 178 b to permit entry of power-packcore assembly 106 into the firing state. Entry into the firing stateinstructs surgical device 100 that SULU 400 is ready to expel fastenerstherefrom.

The actuation of push button switch 172 c, corresponding to a downwardactuation of toggle control button 30, causes controller circuit board142 to provide appropriate signals to motor 152 to close a tool assembly404 of SULU 400 and/or to fire staples from within cartridge assembly408 of SULU 400.

The actuation of push button switch 172 a, corresponding to an upwardactuation of toggle control button 30, causes controller circuit board142 to provide appropriate signals to motor 152 to retract a staple sledand open tool assembly 404 of SULU 400.

The actuation of push button 172 d, corresponding to an actuation oftoggle control button 30 to the right, causes controller circuit board142 to provide appropriate signals to motor 152 to articulate toolassembly 404 to the right relative to body portion 402 of SULU 400.Similarly, the actuation of push button 172 b, corresponding to anactuation of toggle control button 30 to the left, causes controllercircuit board 142 to provide appropriate signals to motor 152 toarticulate tool assembly 404 to the left relative to body portion 402 ofSULU 400.

The actuation of switches 174 a, 174 b (by right-hand thumb of user) orswitches 176 a, 176 b (by left-hand thumb of user), corresponding torespective actuation of right-side pair of control buttons 32 a, 32 b orleft-side pair of control button 34 a, 34 b, causes controller circuitboard 142 to provide appropriate signals to motor 154 to rotate SULU 400relative to surgical device 100. Specifically, actuation of controlbutton 32 a or 34 a causes SULU 400 to rotate relative to surgicaldevice 100 in a first direction, while actuation of control button 32 bor 34 b causes SULU 400 to rotate relative to surgical device 100 in anopposite, e.g., second, direction.

In use, tool assembly 404 of SULU 400 is actuated between opened andclosed conditions as needed and/or desired. In order to fire SULU 400,to expel fasteners therefrom, when tool assembly 404 of SULU 400 is in aclosed condition, safety switch 178 a or 178 b is depressed therebyinstructing surgical device 100 that SULU 400 is ready to expelfasteners therefrom.

With reference to FIGS. 12 and 14, power-pack core assembly 106 ofsurgical device 100 includes a USB connector 180 supported on maincontroller circuit board 142 b of controller circuit board 142. USBconnector 180 is accessible through control plate 160 of power-pack coreassembly 106. When power-pack 101 is disposed within outer shell housing10, USB connector 180 is covered by plate 62 of sterile barrier plateassembly 60 of outer shell housing 10.

As illustrated in FIG. 1 and FIGS. 20-52, surgical device 100 isconfigured for selective connection with one or more different types ofadapters, e.g., adapter 200, and, in turn, the adapter 200 is configuredfor selective connection with one or more different types of loadingunits, e.g., SULU 400, a loading unit 900 (FIG. 69), a multi-use loadingunit (MULU) having a configuration similar to that of SULU 400 orloading unit 900 (FIG. 69), etc.

Adapter 200 is configured to convert a rotation of either of driveconnector sleeve 152 b or 156 b of surgical device 100 into axialtranslation useful for operating a drive assembly 460 and anarticulation link 466 of SULU 400, as illustrated in FIG. 54, and aswill be discussed in greater detail below.

Adapter 200 includes a first drive transmitting/converting assembly forinterconnecting first drive connector sleeve 152 a of surgical device100 and a first axially translatable drive member of SULU 400, whereinthe first drive transmitting/converting assembly converts and transmitsa rotation of first drive connector sleeve 152 a of surgical device 100to an axial translation of the first axially translatable drive assembly460 of SULU 400 for firing.

Adapter 200 includes a second drive transmitting/converting assembly forinterconnecting third drive connector sleeve 156 b of surgical device100 and a second axially translatable drive member of SULU 400, whereinthe second drive transmitting/converting assembly converts and transmitsa rotation of third drive connector sleeve 156 b of surgical device 100to an axial translation of articulation link 466 of SULU 400 forarticulation.

Turning now to FIGS. 21-47, adapter 200 includes an outer knob housing202 and an outer tube 206 extending from a distal end of knob housing202. Knob housing 202 and outer tube 206 are configured and dimensionedto house the components of adapter assembly 200. Outer tube 206 isdimensioned for endoscopic insertion, in particular, that outer tube ispassable through a typical trocar port, cannula or the like. Knobhousing 202 is dimensioned to not enter the trocar port, cannula of thelike. Knob housing 202 is configured and adapted to connect toconnecting portion 108 of handle housing 102 of surgical device 100.

Adapter 200 is configured to convert a rotation of either of first orsecond coupling shafts 64 a, 64 b of surgical device 100 into axialtranslation useful for operating a drive assembly 460 and anarticulation link 466 of SULU 400, as illustrated in FIG. 54 and as willbe described in greater detail below. As illustrated in FIGS. 26 and38-47, adapter 200 includes a proximal inner housing assembly 204rotatably supporting a first rotatable proximal drive shaft 212, asecond rotatable proximal drive shaft 214, and a third rotatableproximal drive shaft 216 therein. Each proximal drive shaft 212, 214,216 functions as a rotation receiving member to receive rotationalforces from respective coupling shafts 64 a, 64 b and 64 c of surgicaldevice 100, as described in greater detail below.

As described briefly above, drive coupling assembly 210 of adapter 200is also configured to rotatably support first, second and thirdconnector sleeves 218, 222 and 220, respectively, arranged in a commonplane or line with one another. Each of connector sleeves 218, 222, 220is configured to mate with respective first, second and third couplingshafts 64 a, 64 c and 64 b of surgical device 100, as described above.Each of connector sleeves 218, 222, 220 is further configured to matewith a proximal end of respective first, second and third proximal driveshafts 212, 214, 216 of adapter 200.

Drive coupling assembly 210 of adapter 200 also includes, as illustratedin FIGS. 26, 38 and 41-44, a first, a second and a third biasing member224, 226 and 228 disposed distally of respective first, second and thirdconnector sleeves 218, 220, 222. Each of biasing members 224, 226 and228 is disposed about respective first, second and third rotatableproximal drive shaft 212, 214 and 216. Biasing members 224, 226 and 228act on respective connector sleeves 218, 222 and 220 to help maintainconnector sleeves 218, 222 and 220 engaged with the distal end ofrespective coupling shafts 64 a, 64 c and 64 b of surgical device 100when adapter 200 is connected to surgical device 100.

In particular, first, second and third biasing members 224, 226 and 228function to bias respective connector sleeves 218, 222 and 220 in aproximal direction. In this manner, during connection of surgical device100 when adapter 200 to surgical device 100, if first, second and orthird connector sleeves 218, 222 and/or 220 is/are misaligned withcoupling shafts 64 a, 64 c and 64 b of surgical device 100, first,second and/or third biasing member(s) 224, 226 and/or 228 arecompressed. Thus, when surgical device 100 is operated, coupling shafts64 a, 64 c and 64 b of surgical device 100 will rotate and first, secondand/or third biasing member(s) 224, 226 and/or 228 will cause respectivefirst, second and/or third connector sleeve(s) 218, 222 and/or 220 toslide back proximally, effectively connecting coupling shafts 64 a, 64 cand 64 b of surgical device 100 to first, second and/or third proximaldrive shaft(s) 212, 214 and 216 of drive coupling assembly 210.

Adapter 200 includes a plurality of force/rotationtransmitting/converting assemblies, each disposed within inner housingassembly 204 and outer tube 206. Each force/rotationtransmitting/converting assembly is configured and adapted totransmit/convert a speed/force of rotation (e.g., increase or decrease)of first, second and third rotatable coupling shafts 64 a, 64 c and 64 bof surgical device 100 before transmission of such rotationalspeed/force to SULU 400.

Specifically, as illustrated in FIG. 26, adapter 200 includes a first, asecond and a third force/rotation transmitting/converting assembly 240,250, 260, respectively, disposed within inner housing assembly 204 andouter tube 206. Each force/rotation transmitting/converting assembly240, 250, 260 is configured and adapted to transmit or convert arotation of a first, second and third coupling shafts 64 a, 64 c and 64b of surgical device 100 into axial translation of articulation bar 258of adapter 200, to effectuate articulation of SULU 400; a rotation of aring gear 266 of adapter 200, to effectuate rotation of adapter 200; oraxial translation of a distal drive member 248 of adapter 200 toeffectuate closing, opening and firing of SULU 400.

As shown in FIGS. 26 and 41-45, first force/rotationtransmitting/converting assembly 240 includes first rotatable proximaldrive shaft 212, which, as described above, is rotatably supportedwithin inner housing assembly 204. First rotatable proximal drive shaft212 includes a non-circular or shaped proximal end portion configuredfor connection with first connector 218 which is connected to respectivefirst coupling shaft 64 a of surgical device 100. First rotatableproximal drive shaft 212 includes a distal end portion 212 b having athreaded outer profile or surface.

First force/rotation transmitting/converting assembly 240 furtherincludes a drive coupling nut 244 rotatably coupled to threaded distalend portion 212 b of first rotatable proximal drive shaft 212, and whichis slidably disposed within outer tube 206. Drive coupling nut 244 isslidably keyed within proximal core tube portion of outer tube 206 so asto be prevented from rotation as first rotatable proximal drive shaft212 is rotated. In this manner, as first rotatable proximal drive shaft212 is rotated, drive coupling nut 244 is translated along threadeddistal end portion 212 b of first rotatable proximal drive shaft 212and, in turn, through and/or along outer tube 206.

First force/rotation transmitting/converting assembly 240 furtherincludes a distal drive member 248 that is mechanically engaged withdrive coupling nut 244, such that axial movement of drive coupling nut244 results in a corresponding amount of axial movement of distal drivemember 248. The distal end portion of distal drive member 248 supports aconnection member 247 configured and dimensioned for selectiveengagement with a drive member 474 of drive assembly 460 of SULU 400(FIG. 54). Drive coupling nut 244 and/or distal drive member 248function as a force transmitting member to components of SULU 400, asdescribed in greater detail below.

In operation, as first rotatable proximal drive shaft 212 is rotated,due to a rotation of first connector sleeve 218, as a result of therotation of first coupling shaft 64 a of surgical device 100, drivecoupling nut 244 is caused to be translated axially along first distaldrive shaft 242. As drive coupling nut 244 is caused to be translatedaxially along first distal drive shaft 242, distal drive member 248 iscaused to be translated axially relative to outer tube 206. As distaldrive member 248 is translated axially, with connection member 247connected thereto and engaged with drive member 474 of drive assembly460 of SULU 400 (FIG. 54), distal drive member 248 causes concomitantaxial translation of drive member 474 of SULU 400 to effectuate aclosure of tool assembly 404 and a firing of tool assembly 404 of SULU400.

With reference to FIGS. 26-31, 45 and 46, second drive converterassembly 250 of adapter 200 includes second proximal drive shaft 214rotatably supported within inner housing assembly 204. Second rotatableproximal drive shaft 214 includes a non-circular or shaped proximal endportion configured for connection with second connector or coupler 222which is connected to respective second coupling shaft 64 c of surgicaldevice 100. Second rotatable proximal drive shaft 214 further includes adistal end portion 214 b having a threaded outer profile or surface.

Distal end portion 214 a of proximal drive shaft 214 is threadablyengaged with an articulation bearing housing 252 a of an articulationbearing assembly 252. Articulation bearing assembly 252 includes ahousing 252 a supporting an articulation bearing 253 having an innerrace 253 b that is independently rotatable relative to an outer race 253a. Articulation bearing housing 252 a has a non-circular outer profile,for example tear-dropped shaped, that is slidably and non-rotatablydisposed within a complementary bore 204 c (FIGS. 45 and 46) of innerhousing hub 204 a.

Second drive converter assembly 250 of adapter 200 further includes anarticulation bar 258 having a proximal portion 258 a secured to innerrace 253 b of articulation bearing 253. A distal portion 258 b ofarticulation bar 258 includes a slot 258 c therein, which is configuredto accept a flag of the articulation link 466 (FIG. 54) of SULU 400.Articulation bar 258 functions as a force transmitting member tocomponents of SULU 400, as described in greater detail below.

With further regard to articulation bearing assembly 252, articulationbearing assembly 252 is both rotatable and longitudinally translatable.Additionally, it is envisioned that articulation bearing assembly 252allows for free, unimpeded rotational movement of SULU 400 when its jawmembers 406, 408 are in an approximated position and/or when jaw members406, 408 are articulated.

In operation, as second proximal drive shaft 214 is rotated due to arotation of second connector sleeve 222, as a result of the rotation ofthe second coupling shaft 64 c of surgical device 100, articulationbearing assembly 252 is caused to be translated axially along threadeddistal end portion 214 b of second proximal drive shaft 214, which inturn causes articulation bar 258 to be axially translated relative toouter tube 206. As articulation bar 258 is translated axially,articulation bar 258, being coupled to articulation link 466 of SULU400, causes concomitant axial translation of articulation link 466 ofSULU 400 to effectuate an articulation of tool assembly 404.Articulation bar 258 is secured to inner race 253 b of articulationbearing 253 and is thus free to rotate about the longitudinal axis X-Xrelative to outer race 253 a of articulation bearing 253.

As illustrated in FIGS. 26, 38, 39, 43, 44 and 47, and as described,adapter 200 includes a third force/rotation transmitting/convertingassembly 260 supported in inner housing assembly 204. Thirdforce/rotation transmitting/converting assembly 260 includes a rotationring gear 266 fixedly supported in and connected to outer knob housing202. Ring gear 266 defines an internal array of gear teeth 266 a (FIG.26). Ring gear 266 includes a pair of diametrically opposed, radiallyextending protrusions 266 b (FIG. 26) projecting from an outer edgethereof. Protrusions 266 b are disposed within recesses defined in outerknob housing 202, such that rotation of ring gear 266 results inrotation of outer knob housing 202, and vice a versa.

Third force/rotation transmitting/converting assembly 260 furtherincludes third rotatable proximal drive shaft 216 which, as describedabove, is rotatably supported within inner housing assembly 204. Thirdrotatable proximal drive shaft 216 includes a non-circular or shapedproximal end portion configured for connection with third connector 220which is connected to respective third connector 122 of surgical device100. Third rotatable proximal drive shaft 216 includes a spur gear 216 akeyed to a distal end thereof. A reversing spur gear 264 inter-engagesspur gear 216 a of third rotatable proximal drive shaft 216 to gearteeth 266 a of ring gear 266.

In operation, as third rotatable proximal drive shaft 216 is rotated,due to a rotation of third connector sleeve 220, as a result of therotation of the third coupling shaft 64 b of surgical device 100, spurgear 216 a of third rotatable proximal drive shaft 216 engages reversinggear 264 causing reversing gear 264 to rotate. As reversing gear 264rotates, ring gear 266 also rotates thereby causing outer knob housing202 to rotate. As outer knob housing 202 is rotated, outer tube 206 iscaused to be rotated about longitudinal axis “X” of adapter 200. Asouter tube 206 is rotated, SULU 400, that is connected to a distal endportion of adapter 200, is also caused to be rotated about alongitudinal axis of adapter 200.

Adapter 200 further includes, as seen in FIGS. 22-25, anattachment/detachment button 272 supported thereon. Specifically, button272 is supported on a stem 273 (FIGS. 25, 26, 41 and 42) projecting fromdrive coupling assembly 210 of adapter 200, and is biased by a biasingmember 274, disposed within or around stem 273, to an un-actuatedcondition. Button 272 includes a lip or ledge 272 a formed therewiththat is configured to snap behind a corresponding lip or ledge 108 bdefined along recess 108 a of connecting portion 108 of handle housing102 of surgical device 100. While stem 273 is illustrated as having arelatively longer length to improve/increase stability of button 272during actuation, it is envisioned that stem 273 may have a relativelyshorter length than the length depicted.

In use, when adapter 200 is connected to surgical device 100, lip 272 aof button 272 is disposed behind lip 108 b of connecting portion 108 ofhandle housing 102 of surgical device 100 to secure and retain adapter200 and surgical device 100 with one another. In order to permitdisconnection of adapter 200 and surgical device 100 from one another,button 272 is depressed or actuated, against the bias of biasing member274, to disengage lip 272 a of button 272 and lip 108 b of connectingportion 108 of handle housing 102 of surgical device 100.

With reference to FIGS. 23-25 and 48-52, adapter 200 further includes alock mechanism 280 for fixing the axial position of distal drive member248. Lock mechanism 280 includes a button 282 slidably supported onouter knob housing 202. Lock button 282 is connected to an actuation bar284 that extends longitudinally through outer tube 206. Actuation bar284 moves upon a movement of lock button 282.

In operation, in order to lock the position and/or orientation of distaldrive member 248, a user moves lock button 282 from a distal position toa proximal position (FIGS. 25 and 41), thereby causing the lock out (notshown) to move proximally such that a distal face of the lock out movesout of contact with camming member 288, which causes camming member 288to cam into recess 249 of distal drive member 248. In this manner,distal drive member 248 is prevented from distal and/or proximalmovement. When lock button 282 is moved from the proximal position tothe distal position, the distal end of actuation bar 284 moves distallyinto the lock out (not shown), against the bias of a biasing member (notshown), to force camming member 288 out of recess 249, thereby allowingunimpeded axial translation and radial movement of distal drive member248.

With reference to FIGS. 32-39, adapter 200 includes an electricalassembly 290 supported on and in outer knob housing 202 and innerhousing assembly 204. Electrical assembly 290 includes a plurality ofelectrical contact blades 292, supported on a circuit board 294, forelectrical connection to pass-through connector 66 of plate assembly 60of outer shell housing 10 of surgical device 100. Electrical assembly290 serves to allow for calibration and communication information (i.e.,identifying information, life-cycle information, system information,force information) to the main controller circuit board 142 b ofpower-pack core assembly 106 via electrical receptacle 149 of power-packcore assembly 106 of surgical device 100. Such communication isdescribed in greater detail below with reference to FIGS. 70-82.

Electrical assembly 290 further includes a strain gauge 296 electricallyconnected to circuit board 294. Strain gauge 296 is provided with anotch 296 a which is configured and adapted to receive stem 204 d of hub204 a of inner housing assembly 204. Stem 204 d of hub 204 a functionsto restrict rotational movement of strain gauge 296. As illustrated inFIGS. 32, 35 and 39, first rotatable proximal drive shaft 212 extendsthrough strain gauge 296. Strain gauge 296 provides a closed-loopfeedback to a firing/clamping load exhibited by first rotatable proximaldrive shaft 212, based upon which power-pack core assembly 106 sets thespeed current limit on the appropriate motor 152, 154, 156.

Electrical assembly 290 also includes a slip ring 298 non-rotatably andslidably disposed along drive coupling nut 244 of outer tube 206. Slipring 298 is in electrical connection with circuit board 294. Slip ring298 functions to permit rotation of first rotatable proximal drive shaft212 and axial translation of drive coupling nut 244 while stillmaintaining electrical contact of electrical contact rings 298 a thereofwith at least another electrical component within adapter 200, and whilepermitting the other electrical components to rotate about firstrotatable proximal drive shaft 212 and drive coupling nut 244.

Electrical assembly 290 may include a slip ring cannula or sleeve 299positioned about drive coupling nut 244 to protect and/or shield anywires extending from slip ring 298.

Turning now to FIGS. 26, 33 and 35, inner housing assembly 204 includesa hub 204 a having a distally oriented annular wall 204 b defining asubstantially circular outer profile, and defining a substantiallytear-drop shaped inner recess or bore 204 c. Bore 204 c of hub 204 a isshaped and dimensioned to slidably receive articulation bearing assembly252 therewithin.

Inner housing assembly 204 includes a ring plate 254 a (FIG. 26) securedto a distal face of distally oriented annular wall 204 b of hub 204 a.Plate 254 a defines an aperture 254 e therethrough that is sized andformed therein so as to be aligned with second proximal drive shaft 214and to rotatably receive a distal tip 214 c of second proximal driveshaft 214. In this manner, distal tip 214 c of second proximal driveshaft 214 is supported and prevented from moving radially away from alongitudinal rotational axis of second proximal drive shaft 214 assecond proximal drive shaft 214 is rotated to axially translatearticulation bearing assembly 252.

As illustrated in FIG. 35, hub 204 a defines a feature (e.g., a stem orthe like) 204 d projecting therefrom which functions to engage notch 296a of strain gauge 296 of electrical assembly 290 to measure forcesexperienced by shaft 212 as surgical device 100 is operated.

With reference to FIGS. 26 and 38, a plate bushing 230 of inner housingassembly 204 is shown and described. Plate bushing 230 extends acrosshub 204 a of inner housing assembly 204 and is secured to hub 204 a byfastening members. Plate bushing 230 defines three apertures 230 a, 230b, 230 c that are aligned with and rotatably receive respective first,second and third proximal drive shafts 212, 214, 216 therein. Platebushing 230 provides a surface against which first, second and thirdbiasing members 224, 226 and 228 come into contact or rest against.

With reference to FIGS. 48-52, adapter 200 includes a distal cap 208extending distally from distal portion 206 b of outer tube 206. Adapter200 further includes a switch 320, a sensor link or switch actuator 340,an annular member 360, and actuation bar 284, each being disposed withinouter tube 206. Switch 320 is configured to toggle in response to acoupling of SULU 400 to distal portion 206 b of outer tube 206. Switch320 is configured to couple to a memory 432 of SULU 400. The memory 423of SULU 400 is configured to store data pertaining to SULU 400 and isconfigured to provide the data to controller circuit board 142 ofsurgical device 100 in response to SULU 400 being coupled to distalportion 206 b of outer tube 206, as detailed below with reference toFIGS. 70-82. Switch 320 is disposed within distal portion 206 b of outertube 206 and is oriented in a proximal direction. Switch 320 is mountedon a printed circuit board 322 that is electrically connected withcontroller circuit board 142 of power-pack 101. As detailed below,power-pack core assembly 106 monitors the 1-wire communication busbetween power-pack core assembly 106 and adapter 200 and is able todetect that SULU 400 is engaged to distal portion 206 b of outer tube206 or that SULU 400 is disengaged from distal portion 206 b of outertube 206 by recognizing that switch 230 has been toggled.

Adapter 200 includes, as illustrated in FIGS. 48 and 51, a switchactuator 340 slidingly disposed within distal portion 206 b of outertube 206. Switch actuator 340 is longitudinally movable between aproximal position, as shown in FIGS. 48 and 51, and a distal position,as shown in FIG. 63. The switch actuator 340 toggles switch 320 duringmovement between proximal and distal positions.

Switch actuator 340 has a proximal end portion 342 a and a distal endportion 342 b. Proximal end portion 342 a of switch actuator 340includes an inner surface 344 that defines an elongated opening 346having a coil spring 348 disposed therein. Coil spring 348 is securedwithin opening 346 between a distal end 344 a of inner surface 344 and aprojection 350 of inner housing 314, which projects through opening 346.

Distal end portion 342 b of switch actuator 340 includes an extension352 having a tapered portion 352 a. Extension 352 is engaged to a firstsurface feature 376 a of annular member 360 when annular member 360 isin a selected orientation relative to extension 352, such that switchactuator 340 is maintained in the proximal position. Switch actuator 340further includes a tab 354 extending from an intermediate portion 356thereof. Coil spring 348 resiliently biases switch actuator 340 towardthe distal position, as shown in FIGS. 48, 61 and 63, in which tab 354actuates or depresses switch 320.

With reference to FIGS. 48-52, adapter 200 includes an annular member360, which is rotatably disposed within inner housing 314 of outer tube206. Annular member 360 extends from a proximal end 362 a to a distalend 362 b and defines a cylindrical passageway 364 therethroughconfigured for disposal of an inner housing 410 b of SULU 400, asdescribed in greater detail below. Annular member 360 includes alongitudinal bar 366 defining an elongated slot 368 along a lengththereof configured for sliding disposal of a fin 420 of inner housing410 b (FIG. 66-68) of SULU 400. Proximal end 362 a includes a first ring370 a and distal end 362 b includes a second ring 370 b, spaced fromfirst ring 370 a along longitudinal bar 366. First ring 370 a includes apair of electrical contacts 372 electrically coupled to switch 320 viawires 374. Electrical contacts 372 are configured to engagecorresponding electrical contacts 430 of SULU 400, such that switch 320and annular member 360 are capable of transferring data pertaining toSULU 400 therebetween, ultimately for communication with power-pack coreassembly 106, as described in greater detail below. It is contemplatedthat a portion of annular member 360 is ring-shaped.

With specific reference to FIGS. 51 and 52, annular member 360 alsoincludes a first surface feature 376 a, and a second surface feature ortab 376 b, each extending from second ring 370 b. Surface feature 376 aof annular member 360 is configured to interface with a first surfacefeature or first lug 412 a (FIGS. 61-64) of SULU 400, such that annularmember 360 is rotatable by and with SULU 400. Specifically, surfacefeature 376 a defines a cavity 378 therein having a squaredconfiguration configured for mating engagement with correspondinglyshaped first lug 412 a of SULU 400. Cavity 378 is shaped and dimensionedto capture first lug 412 a (FIGS. 57 and 58) of SULU 400 upon insertionof SULU 400 into adapter 200, such that annular member 360 is rotatablewith and by SULU 400. Surface feature 376 a of annular member 360 isalso configured to abut extension 352 of switch actuator 340 to maintainswitch actuator 340 in the proximal position.

Annular member 360 is rotatable between a first orientation and a secondorientation. In the first orientation, as shown in FIGS. 51 and 52,surface feature 376 a of annular member 360 is captured between aproximal lip 208 a of distal cap 208 and extension 352 of switchactuator 340. In this configuration, the surface feature 376 a preventsdistal movement of switch actuator 340 from the proximal position to thedistal position, thereby maintaining tab 354 of switch actuator 340 outof engagement with switch 320. Accordingly, surface feature 376 a ofannular member 360 has a dual function for both maintaining switchactuator 340 in the proximal position, out of engagement with switch320, and capturing first lug 412 a of SULU 400 in cavity 378 to providean interface between SULU 400 and annular member 360.

In use, SULU 400 is inserted within the distal end of outer tube 206 ofadapter 200 to mate first lug 412 a of SULU 400 with first surfacefeature 376 a of annular member 360, as shown in FIG. 61. SULU 400 isrotated, in a direction indicated by arrow “C” (FIG. 63), to drive arotation of annular member 360 from the first orientation to the secondorientation. Rotation of annular member 360 from the first orientationto the second orientation disengages surface feature 376 a of annularmember 360 from extension 352 of switch actuator 340 such that coilspring 348 of switch actuator 340 biases switch actuator 340 toward thedistal position, in which switch 320 is toggled, as shown in FIG. 63.

With continued reference to FIG. 52, annular member 360 further includesa projection or tab 376 b extending from second ring 370 b. Tab 376 bhas a planar configuration and is configured to resist and/or preventinadvertent rotation of annular member 360 within inner housing 314 whenSULU 400 is not engaged to adapter 200. With specific reference to FIG.52, when annular member 360 is in the first orientation, tab 376 b issecured between a projection 208 b of distal cap 208 and a distal end284 a of actuation bar 284. Rotation of annular member 360 from thefirst orientation to the second orientation is resisted and/or preventeduntil actuation bar 284 is moved to a second configuration, as describedbelow. In this way, tab 376 b ensures that first surface feature 376 aof annular member 360 is maintained in abutment with extension 352 ofswitch actuator 340 thereby maintaining switch actuator 340 in theproximal position until SULU 400 is engaged to adapter 200.

With reference to FIGS. 36, 52, 62 and 64, and as discussed brieflyabove, adapter 200 further includes a lock mechanism 280 having a button282 slidably supported on outer knob housing 202, and an actuation bar284 extending from button 282. Actuation bar 284 extends longitudinallythrough outer tube 206. Specifically, actuation bar 284 is slidinglydisposed within or along inner housing 314 of adapter 200 and isresiliently biased toward a first configuration, as shown in FIG. 64. Inthe first configuration, a distal end or extension 284 a of actuationbar 284 is engaged with distal cap 208. Extension 284 a of actuation bar284 is configured for engagement with a second lug 412 b (FIG. 64) ofSULU 400 upon insertion and rotation of SULU 400 into adapter 200. Asshown in FIG. 62, SULU 400 engages adapter 200 and actuation bar 284 inthe first configuration, second lug 412 b of SULU 400 is captured in anenclosure 286 defined by extension 284 a of actuation bar 284 and distalcap 208.

As illustrated in FIGS. 1 and 54-56, SULU is designated as 400. SULU 400includes a proximal body portion 402 and a tool assembly 404. Proximalbody portion 402 is releasably attached to a distal cap 208 of adapter200 and tool assembly 404 is pivotally attached to a distal end ofproximal body portion 402. Tool assembly 404 includes an anvil assembly406 and a cartridge assembly 408. Cartridge assembly 408 is pivotal inrelation to anvil assembly 406 and is movable between an open orunclamped position and a closed or clamped position for insertionthrough a cannula of a trocar. Proximal body portion 402 includes atleast a drive assembly 460 and an articulation link 466.

Referring to FIG. 54, drive assembly 460 includes a flexible drive beam464 having a distal end and a proximal engagement section. A proximalend of the engagement section includes diametrically opposed inwardlyextending fingers that engage a hollow drive member 474 to fixedlysecure drive member 474 to the proximal end of beam 464. Drive member474 defines a proximal porthole which receives connection member 247 ofdrive tube 246 of first drive converter assembly 240 of adapter 200 whenSULU 400 is attached to distal cap 208 of adapter 200.

Proximal body portion 402 of SULU 400 includes an articulation link 466having a hooked proximal end which extends from a proximal end of SULU400.

As illustrated in FIG. 54, cartridge assembly 408 of tool assembly 404includes a staple cartridge removably supported in a carrier. The staplecartridge defines a central longitudinal slot, and three linear rows ofstaple retention slots positioned on each side of the longitudinal slot.Each of the staple retention slots receives a single staple and aportion of a staple pusher. During operation of surgical device 100,drive assembly 460 abuts an actuation sled and pushes actuation sledthrough the cartridge. As the actuation sled moves through thecartridge, cam wedges of the actuation sled sequentially engage thestaple pushers to move the staple pushers vertically within the stapleretention slots and sequentially ejects a single staple therefrom forformation against an anvil plate of anvil assembly 406.

To fully disengage SULU 400 from adapter 200, SULU 400 is axiallytranslated, in a distal direction, through distal cap 208, and out ofouter tube 206 of adapter 200. It is contemplated that upon surgicaldevice 100 detecting that SULU 400 is not engaged to adapter 200, powermay be cut off from adapter 200, and alarm (e.g., audio and/or visualindication) may be issued, and combinations thereof, as detailed below.

With reference to FIGS. 54-60, SULU 400 further includes an outerhousing 410 a and an inner housing 410 b disposed within outer housing410 b. First and second lugs 412 a, 412 b are each disposed on an outersurface of a proximal end 414 of outer housing 410 a. First lug 412 ahas a substantially rectangular cross-section corresponding to cavity378 of surface feature 376 a of annular member 360 of adapter 200.Second lug 412 b has a substantially rectangular cross-sectioncorresponding to inner groove 208 c of distal cap 208 of adapter 200.Proximal end 414 of outer housing 410 a is sized and dimensioned to beinserted through distal cap 208 to engage adapter 200.

Outer housing 410 a defines a first notch 416 a and a second notch 416 bin a proximal-most edge thereof. First notch 416 a is configured forsliding receipt of a tapered fin 420 extending from inner housing 410 b.At least a portion of fin 420 is configured for disposal in slot 468defined in longitudinal bar 366 of annular member 360 to facilitateinsertion of inner housing 410 b into annular member 360. Second notch416 b is configured for a snap fit engagement with a pair of parallel,resilient fingers 422 of inner housing 410 b. Second notch 416 bgenerally has a rectangular configuration with a pair of grooves 418defined therein. Each finger 422 has a mating part 424 configured formating engagement with one respective groove 418 of second notch 416 b.Outer housing 410 a further defines a pair of channels 426 defined in aninterior surface 428 thereof and disposed on either side of first notch416 a. Each channel 426 of outer housing 410 a is configured fordisposal of a portion of an electrical contact 430 of inner housing 410b, as described in greater detail below.

In use, fin 420 and fingers 422 of inner housing 410 b are aligned withfirst and second notches 416 a, 416 b of outer housing 410 a,respectively, and inner housing 410 b is axially translated within outerhousing 410 a, until mating parts 424 of fingers 422 are captured ingrooves 418 of second notch 416 b to capture inner housing 410 b withinouter housing 410 a.

SULU 400 further includes a memory 432 disposed within or on innerhousing 410 b. Memory 432 includes a memory chip 434 and a pair ofelectrical contacts 430 electrically connected to memory chip 434.Memory chip 434 is configured to store one or more parameters relatingto SULU 400. The parameter includes a serial number of a loading unit, atype of loading unit, a size of loading unit, a staple size, informationidentifying whether the loading unit has been fired, a length of aloading unit, maximum number of uses of a loading unit, and combinationsthereof. Memory chip 434 is configured to communicate to surgical device100 a presence of SULU 400 and one or more of the parameters of SULU 400via electrical contacts 430, upon engagement of SULU 400 with adapter200, as detailed below.

Electrical contacts 430 are disposed on an outer surface of innerhousing 410 b and are configured to engage electrical contacts 372 ofannular member 360 upon insertion of SULU 400 into adapter 200. Aproximal end of each electrical contact 430 has a bent portion 436extending beyond a proximal-most edge of outer housing 410 a of SULU 400when inner housing 410 b is secured within outer housing 410 a, as shownin FIGS. 57 and 58. Bent portions 436 of electrical contacts 430 of SULU400 engage electrical contacts 372 of annular member 360 upon insertionof SULU 400 within annular member 360 of adapter 200. This connectionbetween the contacts 372 and 430 allows for communication between memorychip 434 of SULU 400 and controller circuit board 142 of surgical device100. In particular, controller circuit board 142 of surgical device 100receives one or more parameters pertaining to SULU 400 and that SULU 400is engaged to adapter 200.

In operation, SULU 400 is inserted into distal end 206 b of outer tube206 of adapter 200 to matingly engage first lug 412 a of SULU 400 withincavity 378 of surface feature 376 a of annular member 360, as shown inFIGS. 61-65. The insertion of SULU 400 within adapter 200 also engagessecond lug 412 b with extension 284 a of actuation bar 284 to moveactuation bar 284 in a proximal direction, as shown in the directionindicated by arrow “B” in FIG. 62, to the second configuration, and outof abutment with tab 376 b of annular member 360. In this way, extension284 a of actuation bar 284 no longer prevents annular member 360 fromrotating. With SULU 400 in this initial insertion position withinadapter 200, switch actuator 340 remains in the proximal position out ofengagement with switch 320.

To engage SULU 400 with adapter 200, SULU 400 is rotated, in a directionindicated by arrow “C” in FIG. 63, to drive a rotation of annular member360, via the mating engagement between first lug 412 a of SULU 400 andsurface feature 376 a of annular member 360, from the first orientationto the second orientation. The rotation of annular member 360 from thefirst orientation to the second orientation displaces surface feature376 a of annular member 360 away from extension 352 of switch actuator340. With surface feature 376 a out of engagement with extension 352 ofswitch actuator 340, switch actuator 340 moves from the proximalposition, as shown in FIGS. 48 and 51, to the distal position, as shownin FIG. 63, via coil spring 348. As switch actuator 340 moves to thedistal position, tab 354 of switch actuator 340 toggles switch 320,e.g., by depressing switch 320, as shown in FIG. 63. Depressing oractuating switch 320 communicates to surgical device 100 that SULU 400is engaged with adapter 200 and is ready for operation.

The rotation of SULU 400 also moves second lug 412 b of SULU 400 into aninner groove 208 c defined in distal cap 208 of adapter 200 and out ofengagement with extension 284 a of actuation bar 284. The resilient biasof actuation bar 284 drives an axial translation of actuation bar 284,in a direction indicated by arrow “D” in FIG. 64, to dispose actuationbar 284 into the first configuration. With actuation bar 284 in thefirst configuration, second lug 412 b of SULU 400 is captured withinenclosure 286 defined by extension 284 a of actuation bar 284 and innergroove 208 c of distal cap 208 of adapter 200. SULU 400 is preventedfrom moving distally out of enclosure 286 due to an inner ledge 208 d ofinner groove 208 c of distal cap 208 of adapter 200, and is preventedfrom rotating, in a direction indicated by arrow “E” shown in FIG. 64,due to extension 284 a of actuation bar 284. Therefore, SULU 400 isreleasably, engaged to adapter 200.

To selectively release SULU 400 from adapter 200, a practitionertranslates or pulls actuation bar 284 in a proximal direction, such thatextension 284 a of actuation bar 284 is no longer blocking second lug412 b of SULU 400 and SULU 400 can be rotated. SULU 400 is rotated, in adirection indicated by arrow “F” in FIG. 63, to move second lug 412 b ofSULU 400 out of abutment with inner ledge 208 d of distal cap 208. Therotation of SULU 400 also drives the rotation of annular member 360 fromthe second orientation to the first orientation via the matingengagement of first lug 412 a of SULU 400 and surface feature 376 a ofannular member 360. As annular member 360 rotates, surface feature 376 arides along tapered portion 352 a of extension 352 of switch actuator340 to drive switch actuator 340 in a proximal direction until annularmember 360 is in the first orientation and switch actuator 340 is in theproximal position, out of engagement with switch 320. Upon tab 354 ofswitch actuator 340 disengaging switch 320, switch 320 is toggled, whichcommunicates to surgical device 100 that SULU 400 may be pulled out ofadapter 200.

In operation, SULU 400, with inner housing 410 b disposed within outerhousing 410 a, is manipulated to align fin 420 of inner housing 410 band electrical contacts 430 of inner housing 410 b with longitudinal bar366 of annular member 360 and electrical contacts 372 of annular member360, respectively. SULU 400 is inserted within the distal end of adapter200 thereby engaging first lug 412 a of outer housing 410 a withinsurface feature 376 a of annular member 360 and forming a wiping contactbetween electrical contacts 430 of inner housing 410 b and electricalcontacts 372 of annular member 360, as shown in FIGS. 63 and 64.

As described above with reference to FIGS. 61 and 62, upon the initialinsertion of SULU 400 into adapter 200, switch actuator 340 remainsdisengaged from switch 320. With switch 320 in the unactuated state,there is no electrical connection established between memory chip 434 ofSULU 400 and controller circuit board 142 of surgical device 100. Asdiscussed above, upon a rotation of SULU 400, SULU 400 engages adapter200 and switch actuator 340 toggles switch 320 to actuate switch 320.With switch 320 in the actuated state, an electrical connection isestablished between memory chip 434 and controller circuit board 142 ofsurgical device 100, through which information about SULU 400 iscommunicated to controller circuit board 142 of surgical device 100.Upon both the actuation of switch 320 and the establishment of a wipingcontact between electrical contacts 430 of inner housing 410 b andelectrical contacts 372 of annular member 360, surgical device 100 isable to detect that SULU 400 has been engaged to adapter 200 and toidentify one or more parameters of SULU 400.

Referring to FIGS. 53 and 69A-69D, SULU 400, as detailed above, is asingle-use, EGIA-type loading unit. However, as noted above, other typesof loading units are also capable of being used with surgical device 100including EEA loading unit 900A, MULU 900B, transverse loading unit900C, and curved loading unit 900D. As detailed below, the particularloading unit utilized is recognized by power-pack core assembly 106 toenable appropriate operation thereof.

With reference to FIG. 69A, EEA loading unit 900A includes a proximalbody portion 902A and tool assembly 904A for circular stapling andcutting, e.g., during the course of an end-to-end anastomosis procedure.Similar to SULU 400 (FIG. 53), EEA loading unit 900A includes aninternal memory chip that includes a memory configured to store datapertaining to loading unit 900A. Generally, loading unit 900A isoperated when attached to adapter 200 (FIG. 20) in a similar manner asdescribed above with regard to SULU 400 (FIG. 53).

With reference to FIGS. 69B1 and 69B2, MULU 900B is similar to SULU 400(FIG. 53) and includes a proximal body portion (not shown) and a toolassembly having an anvil assembly 906B and a cartridge assembly 908B.However, MULU 900B differs from SULU 400 (FIG. 53) mainly in thatcartridge assembly 908B is configured to removably receive a staplecartridge 910B that, after use, is replaced with a replacement staplecartridge 910B for subsequent use of MULU 900B. Alternatively, MULU 900Bmay contain multiple staple cartridges disposed therein to enablerepeated use without requiring replacement of staple cartridge 910B.Similar to SULU 400 (FIG. 53), MULU 900B includes an internal memorychip that includes a memory configured to store data pertaining to MULU900B. Generally, MULU 900B is operated when attached to adapter 200(FIG. 20) in a similar manner as described above with regard to SULU 400(FIG. 53).

Transverse loading unit 900C and curved loading unit 900D, asillustrated in FIGS. 69C and 69D, respectively, are still furtherconfigurations of loading units configured for use with surgical device100. Similar to SULU 400 (FIG. 53) and the other embodiments of loadingunits detailed herein, transverse loading unit 900C and curved loadingunit 900D each include an internal memory chip having a memoryconfigured to store data pertaining to the respective loading unit 900C,900D and are generally operated when attached to adapter 200 (FIG. 20)in a similar manner as described above.

Turning now to FIGS. 70-82 the communication, safety, and controlfeatures of surgical device 100 are described. As noted above,controller circuit board 142 of power-pack core assembly 106 includesmotor controller circuit board 142 a and main controller circuit board142 b. Controller circuit board 142 is coupled to battery circuit board140 and a switch board 177 of switch assembly 170 (FIG. 15).

Main controller circuit board 142 b includes master chip 157 andsupports memory 165, which in an embodiment, is a micro SD memory. Maincontroller circuit board 142 b further includes a 1-wire communicationsystem including three 1-wire buses. A 1-wire master chip 166 of maincontroller circuit board 142 b controls communications across three1-wire buses 167, 169, 171. Although described herein as a 1-wirecommunication system, it is contemplated that other suitablecommunication systems for enabling the functionality detailed herein mayalso be provided.

First 1-wire bus 167 establishes a communication line between masterchip 157 and motor controller circuit board 142 a, which connects tobattery circuit board 140 of battery 144 when battery 144 is present,thereby establishing a communication line between power-pack coreassembly 106 and battery 144.

Second 1-wire bus 169 establishes a communication line between masterchip 157 and a switchboard/adapter intermediate 175, which includeselectrical adapter interface receptacle 149, and is configured toconnect to a 1-wire memory chip of circuit board 294 of adapter 200 whenadapter 200 is present. Switchboard/adapter intermediate 175 alsocouples switch board 177 with main controller board 142 b via a thirdribbon cable 142 e. Second 1-wire bus 169 establishes a communicationline between power-pack core assembly 106 and adapter 200 and alsoenables information stored in the 1-wire memory chip of circuit board294 of adapter 200 to be accessed, updated, and/or incremented bypower-pack core assembly 106. Circuit board 294 of adapter 200, inaddition to having the 1-wire chip, includes a memory and electricalcontacts 292 that enable electrical connection to the power-pack coreassembly 106 to allow for calibration and communication of data andcontrol signals therebetween. The memory is configured to store datarelating to adapter 200 such as unique ID information (electronic serialnumber); type information; status information; whether a loading unithas been detected, identified, and verified; usage count data; andassumed autoclave count data. Distal electrical contacts 272 of adapter200, as noted above, are configured to electrically couple with thecorresponding electrical contacts 330 of a loading unit engagedtherewith, e.g., SULU 400, for communication therewith, while toggleswitch 230 permits the power-pack core assembly 106 to detect thepresence of SULU 400. The memory of the SULU 400 stores data relating toSULU 400 such as a serial number, the type of the loading unit, the sizeof the loading unit, the staple size, the length of the loading unit,and an indication of whether the loading unit has been fired. Power-packcore assembly 106 is capable of reading this information stored in thememory of SULU 400 via adapter 200.

Third 1-wire bus 171 enables communication between master chip 157 inpower-pack core assembly 106 and the 1-wire memory chip of outer shellhousing 10. As detailed above, the 1-wire chip in outer shell housing 10includes a memory that stores a unique ID of outer shell housing 10 andis capable of being updated to mark outer shell housing 10 as “used.”Electrical contacts associated with the outer shell housing 10 form partof third 1-wire bus 171 and enable communication between power-pack coreassembly 106 and 1-wire chip of the outer shell housing 10.

Power-pack core assembly 106 further includes and/or is coupled tovarious hardware components (some of which have been detailed above)that facilitate the various functions of power-pack core assembly 106including: a Wifi board 182, the display screen 146, an accelerometer184, the universal serial bus (USB) port 180, an infrared detectionmodule 186, a real-time clock (RTC), an expansion port 188, and the FPGA162, which as mentioned above enables communication between maincontroller 157 and motor controllers “MC0,” MC1,” “MC2” of motorcontroller circuit board 142 a. Wifi board 182 and/or USB port 180 areused for communicating data collected by power-pack core assembly 106,adapter 200, and/or loading unit 300 to an external communicationsystem. Accelerometer 184 enables determination of whether power-packcore assembly 106 has been manipulated, rotated, moved, etc. The RTCprovides a reference from which the various time and/orduration-dependent functionality may be established.

FIG. 71 is a block diagram of a simplified system architecture 1100 forcontrolling components of surgical device 100 (FIG. 1). Architecture1100 includes a processor 1102 in operable communication with a memory1104, which has various modules that include instructions for surgicaldevice 1000 to operate in a desired manner, based on received user inputor detected data. Processor 1102 is included on one or more of theboards of controller circuit board 142 (FIG. 70) and is made up of oneor more devices. Here, for example, master chip 157, motor controllers“MC0,” “MC1,” “MC2,” 1-wire master chip 166, and other controllers makeup processor 1102 (see FIG. 70). Memory 1104 is computer-readable mediaand resides in one or more locations, such as, for example, memory 165of main controller circuit board 142 and the 1-wire memory chips ofadapter 200 and outer shell housing 10 (see FIGS. 1 and 70). In anembodiment, memory 1104 may include one or more solid-state storagedevices such as flash memory chips. Alternatively or in addition to theone or more solid-state storage devices, memory 1104 may include one ormore mass storage devices connected to the processor 1102 through a massstorage controller (not shown) and a communications bus (not shown).Although the description of computer-readable media contained hereinrefers to a solid-state storage, it should be appreciated by thoseskilled in the art that computer-readable storage media can be anyavailable media that can be accessed by the processor 1102. That is,computer readable storage media includes non-transitory, volatile andnon-volatile, removable and non-removable media implemented in anymethod or technology for storage of information such ascomputer-readable instructions, data structures, program modules orother data. For example, computer-readable storage media includes RAM,ROM, EPROM, EEPROM, flash memory or other solid state memory technology,CD-ROM, DVD, Blu-Ray or other optical storage, magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other medium which can be used to store the desired informationand which can be accessed by processor 1102.

Memory 1104 includes an application 1106, which stores instructions forthe operation of surgical device 100 (FIG. 1), and a database 1108,which stores collected data relating to surgical device 100 (FIG. 1).Application 1106 includes a mode module 1112, an initialization module1114, a charging module 1116, a validation module 1118, a calibrationmodule 1120, and an operation module 1122. Each of these modules will bedescribed in greater detail below.

Mode module 1112 instructs a power-pack (e.g., power-pack core assembly106 (FIG. 13)) to enter or exit operational modes and enters/exits thesemodes depending upon its condition, last use, motion, whether anycomponents are attached, and/or whether it is connected to a charger.Specifically, the power-pack is transitionable from a ship mode and,thereafter, between a standby mode, a sleep mode, and an active mode.FIG. 72 is a diagram of a method 1200 depicting a flow by which thepower-pack enters/exits the various modes thereof. Initially, thepower-pack is in the ship mode at S1202. When the power-pack entersinitial startup at S1204, it undergoes an initialization wherein theship mode is permanently exited at S1206. It is contemplated that thebattery of the power-pack be provided in an un-charged state and, assuch, initialization begins upon connection of the power-pack with thecharger. Until such initialization, the power-pack remains in ship modeat S1202. Once the ship mode has been exited, the power-pack istransitional between the standby mode, the sleep mode, and the activemode, and enables and/or disables certain functionality based upon itsmode.

Entry into one of the various modes depends on whether the power-packincludes a clamshell, e.g., outer shell housing 10, engaged thereabout.Accordingly, with continued reference to FIG. 72, a determination ismade as to whether the outer shell housing is attached to the power-packat S1208. With respect to surgical device 100, this determination ismade by the master chip 157 scanning third 1-wire bus 171 in search of a1-wire memory chip of outer shell housing 10 (see FIGS. 1 and 70). Whenno outer shell housing is attached, an “insert clamshell” screen isdisplayed on a display screen to communicate to the user that no outershell housing is attached to the power-pack. While the outer shellhousing is not attached to the power-pack, button presses do not elicitmotor responses. For example, open, close, safety and articulate buttonsdo not function. However, the power-pack is able to connect to anexternal communication system, and a screen depicting connection to theexternal communication system is displayed on the display screen. If arotate button is pressed, a current power-pack statistics screen isdisplayed for a desired duration, for example, five (5) seconds.

Next, a determination is made as to whether the power-pack has been usedat S1210. Usage includes, for example, placing the power-pack on thecharger for recharging the battery, e.g., battery 144 (FIG. 70),pressing any of the various buttons on the power-pack, attaching anouter shell housing to the power-pack, or manipulating the power-pack(as determined by the accelerometer). When the power-pack has been idlefor a time period that is greater than a first predetermined thresholdduration, e.g., thirty (30) seconds of no usage, the power-pack entersstandby mode at S1212. Otherwise, the power-pack enters an active modeat S1214. As indicted by S1230, if entry into the active mode at S1214is triggered via connection of an outer shell housing to the power-pack,the active mode at S1220, which is detailed below, is achieved.

At S1216, while in standby mode, another determination is made as towhether the power-pack is being used. Here, a determination is made asto whether the power-pack has been idle for a time period that isgreater than a second predetermined threshold duration, where the secondpredetermined threshold duration of step S1216 is greater than the firstpredetermined threshold duration of step S1210, for example, in a rangeof five (5) to twenty (20) minutes, e.g., fifteen (15) minutes. If atS1216 the power-pack does not remain idle for a time period that isgreater than the predetermined threshold duration, the power-pack entersan active mode at S1214. If the power-pack does remain idle for a timeperiod that is greater than the predetermined threshold duration, thepower-pack exits the standby mode and enters a sleep mode at S1218.Method 1200 then proceeds to S1216 to determine whether to exit sleepmode and enter active mode at S1214 or remain in sleep mode at S1218.

Returning to S1208, when an outer shell housing is attached to thepower-pack, the active mode is entered at S1220 so that the power-packis ready for use. For instance, the power-pack monitors 1-wire bus 171(FIG. 70) at a minimum rate of 1 Hz for the presence of attachment of anouter shell housing 10 (FIG. 1). A determination then is made at S1222as to whether the power-pack is in use. Usage includes, for example,motion of the power-pack, pressing any of the various buttons, detectionof another outer shell housing (e.g., if the outer shell housing isremoved and replaced with another outer shell housing), or attachment ofan adapter. When the power-pack is in use, the power-pack remains in theactive mode and returns to S1220. When the power-pack is not in useafter a predetermined threshold duration, for example, after one (1)minute of non-usage, the power-pack enters the standby mode at S1224.During the standby mode, the power-pack returns to S1222 continuing tomonitor whether usage occurs. In an embodiment, if the outer shellhousing is a demonstration component, motion does not cause thepower-pack to exit the standby mode. If an adapter, e.g., adapter 200,is already attached to the power-pack, attachment of a loading unit,e.g., SULU 400 (FIG. 1), loading unit 900A (FIG. 69A), MULU 900B (FIGS.69B1 and 69B2), loading unit 900C (FIG. 69C), or loading unit 900D (FIG.69D), to the adapter will also cause the power-pack to exit the standbymode and to enter the active mode at S1220. Multi-use loading units,e.g., MULU 900B (FIGS. 69B1 and 69B2), include replaceable staplecartridges, and hence, may be referred to as a reload. For purposes ofconsistency in describing the methods performed by application 1106,loading units and reloads for use with multi-use loading units will bereferred to below simply as “reloads.”

Initialization module 1114 controls initialization of the power-pack. Inparticular, initialization module 1114 includes instructions for thepower-pack to perform a plurality of self-tests at initialization, whichoccurs when the power-pack exits the ship mode, the power-pack isremoved from the charger, the power-pack is woken up from sleep mode, orwhen initiated by the user. The initialization self-tests include a testof the display screen, a test of the memory of the power-pack, an RTCtest, an FPGA communication test, a test of the motor and driveelectronics, a test of the accelerometer, a button active test, aplurality of 1-wire tests, and a use-remaining test.

Turning now to FIG. 73, a flow diagram is provided depicting a method1300 for initializing the power-pack. Initialization begins at S1302when the power-pack exits the ship mode, the power-pack is removed fromthe charger, the power-pack is woken up from the sleep mode, or wheninitiated by the user. Although any one of the initialization tests canbe initially performed, for the purposes of this description, thedisplay screen is initially tested at S1304. The display test includesverifying communication capability between the power-pack and thedisplay controller, turning on all pixels to the color white for 500milliseconds (mS), and, upon completion, displaying the “welcome” screenon the display screen. Next, a determination is made at S1306 as towhether any of the initialization tests have not yet been performed. Ifso, a next test to be performed is identified at S1308. If not, method1300 ends.

If identified as being next to be performed, the clock is verified atS1310. In an embodiment, testing is performed to determine whether theclock is functional. Next, S1306 is performed, and S1308, if needed, isperformed to identify a next test.

If identified as being the next test to be performed, the memory of thepower-pack is verified at S1312. For example, verification includes oneor more of verifying the integrity of the code stored in the programmemory of the power-pack, the integrity of the external SRAM, theability to communicate with the SD memory, e.g., memory 165 (FIG. 70),and the integrity of the file system on the SD card. In an embodiment,if the integrity of the code is not verified, method 1400 is performedas shown in FIG. 74. In particular, if verification of the code fails,no further operation is possible at S1402 and method 1400 ends. If theverification operation fails, method 1400 at S1402 is performed (i.e.,no further operation is possible) and a fault tone occurs at S1404. Ifverification of the ability to communicate with the SD memory fails,method 1400 at S1402 is performed (i.e., no further operation ispossible) and a fault tone occurs at S1404. The fault tone is a singletone or a series of tones within a frequency range. For example, thefault tone is a pattern of tones including a tone within a frequencyrange of 500 Hertz (Hz)±50 Hz with a duration of 225 mS followed by atone within a frequency range of 250 Hertz (Hz)±25 Hz with a duration of225 mS and so on. If the integrity of the file system on the SD card isnot verified, the fault tone also occurs at S1404. After the memory istested, method 1300 advances to S1306, where a determination is made asto whether any more of the initialization tests remain to be performed,and, if needed, identifying a next test to be performed at S1308.

In an event in which communication verification is identified as thenext test to be performed, step S1314 is performed. In particular, anFPGA communication test is performed to verify that the FPGA isoperational. If the FPGA communication test fails, S1402 (no furtheroperation is possible), and S1406 (where an error screen is displayed onthe display) are performed. Method 1300 advances to S1306 and S1308, ifneeded, to identify a next test to be performed.

If not yet already performed, a determination is made as to whether anadapter is attached at S1316, and if not, a test of the motor and driveelectronics is performed to verify the motors of the power-pack atS1318. In an event in which any of the motors are unable to attain acommanded position, no further operation is possible as indicated inS1402. If one or more of the motors fail, a fault tone occurs as S1404,and an error screen is displayed at S1408.

If at S1316, the adapter is identified as being attached or theelectronics are verified, method 1300 advances to S1306 and, if needed,to S1308 to identify a next test to be performed. If an accelerometercheck has not yet been performed, method 1300 advances to S1320, duringwhich verification is made as to whether the accelerometer of thepower-pack is functional. If the accelerometer is not functional, method1300 advances to method 1500 of FIG. 75. In particular, all operationsincluding firing are possible at S1501, a fault tone occurs (S1504), andan error screen is displayed on the power-pack (S1506). If theaccelerometer is functional, method 1300 advances to S1306 and, ifneeded, to S1308 which, as noted above, is performed to identify a nexttest to be performed.

If identified as the next test to be performed, wireless functionalitiesare verified at S1322. If the wireless functionalities are verified,method 1300 advances to S1306, and if needed, to S1308 to identify anext test to be performed. If the wireless functionalities are notverified, all operations including firing are possible (S1501), a faulttone occurs (S1504) and an error screen is displayed on the power-pack(S1506).

Verification is made with regard to whether a button is active at S1324,if not already performed. In the event that the button is active duringinitialization method 1300, user operations are ignored until the buttonis deactivated. Method 1300 then advances to S1306, where adetermination is made as to whether any other initialization test hasnot been performed. If so, a next test to be performed is identified atS1308. If not, method 1300 ends.

If identified as a next test to be performed, the operability of thebattery is verified at S1326. In an embodiment, numerous tests areperformed on the battery. A method 1600 for testing the battery isprovided in FIG. 76. The battery is initialized by disabling abroadcasting capability of the battery to prevent unsolicited messagesfrom being sent. In the event that communication with the battery failsat 1602, the method 1600 advances to FIG. 75, where all operationsexcept firing are possible (1502), a fault tone occurs (1504), and anerror screen is displayed on the power-pack (1506).

If communication does not fail, method 1600 proceeds to perform one ofthe battery tests. Although any of the tests can be initially performed,for the purposes of this description, method 1600 performs the batterycapacity (C_(Batt)) test at S1608. The battery capacity may be displayedon the display. In an embodiment, battery capacity testing is performedby determining whether the battery capacity is above a threshold value(e.g., z<C_(Batt)) at S1610. If the battery capacity is not above thethreshold value, a determination is made as to whether the batterycapacity is within a first range (e.g., y<C_(Batt)<z), where thethreshold value is an upper limit of the first range at S1612. If so, atone occurs and a “low battery” error screen is displayed at S1614. Inan embodiment, the tone is one that is distinguishable from the faulttone and that indicates a low battery. For example, a sequenceindicating a low battery occurrence may include a tone at a frequency of1000 Hz for 50 mS, followed by no tone, followed by a tone at afrequency of 800 Hz for 50 mS, followed by no tone, followed by a toneat a frequency of 600 Hz, followed by no tone, followed by a tone at afrequency of 400 Hz, followed by no tone.

If the battery capacity is not within the first range, a determinationis made at S1616 as to whether the battery capacity is within a secondrange (e.g., x<C_(Batt)<y), where an upper limit of the second range isequal to or below a lower limit of the first range. If the batterycapacity is within a second range, a tone indicating an insufficientbattery occurs and an “insufficient battery” error screen is displayedat S1618. The tone indicating an insufficient battery differs from thetone indicating a low battery. In an embodiment, the low battery tone isa series of tones each at a frequency of 400 Hz±40 Hz in a pattern of onfor 50 mS, then off for 50 mS repeated twelve (12) times, and endingwith the tone being played for 750 mS.

If the battery capacity is not within the second range and thus, isbelow a lower limit of the second range (e.g., C_(Batt)<x), then a toneindicating a dead battery occurs and a “dead battery” error screen isdisplayed at S1620. The tone indicating a dead battery differs than thetones indicating an insufficient battery or a low battery. In anembodiment, a dead battery is indicated by a series of tones each at afrequency of 400 Hz±40 Hz in a pattern of on for 100 mS, then off for 50mS, where the pattern is repeated twelve (12) times, and a last tone inthe series is played for 750 mS.

Referring again to S1610, if the battery capacity is above the thresholdvalue (z), method 1600 proceeds to S1604, where a determination is madeas to whether any of the battery tests have not yet been performed. Ifso, a next battery test to be performed is identified at S1606. If not,method 1600 ends.

If not yet already performed, the battery temperature is tested atS1622. A determination is made as to whether the battery temperature isin a desired range at S1624. In an example, the desired range is 15 to70 degrees Celsius (° C.). In another embodiment, the desired range iswider than or overlaps the aforementioned range. In yet anotherembodiment, the desired range is above or below the aforementionedrange. If the battery temperature is not within the desired range,either exceeding or falling below the range, a fault tone occurs atS1626. If the battery temperature is within the desired range, method1600 returns to S1604 and S1608 to identify a next test to be performed,if any.

If not already performed, a battery end-of-life test is performed at1628 to test a battery full charge capacity for end-of-life condition.In this regard, a determination is made as to whether the battery fullcharge capacity is less than or equal to a predetermined percentage ofdesign capacity at S1630. In an example, the predetermined percentage isabout 82%. If the battery full charge capacity is less than or equal tothe predetermined percentage, the power-pack is operable except forentering a firing state at S1632. If the battery full charge capacity isgreater than the predetermined percentage, the test fails and fault toneoccurs along with a display of the error on the error screen at S1634. Abattery charge cycle count is also tested. In particular, adetermination is made as to whether the battery charge cycle count isequal to or over a predetermined number of charge cycles at S1636. In anembodiment, the predetermined number of charge cycles is three hundred(300) charge cycles. If the battery charge cycle count is equal to orover the predetermined number of charge cycles, the power-pack coreassembly 106 can be operated except for entering a firing state, a faulttone occurs, and an error screen is shown on the display at S1638.Otherwise, method 1600 advances to S1604, and to S1606, if needed.

Returning to FIG. 73, after the battery testing, method 1300 proceeds toS1306, to determine whether any of the initialization tests have not yetbeen performed. If so, a next test to be performed is identified atS1308. If not, method 1300 ends.

In an instance in which wire testing has not yet been performed, aplurality of wire tests are performed at S1328 to verify communicationcapability between the master chip of the power-pack and the variouscomponents of the system along the 1-wire bus system. The tests are alsoemployed to verify and record identifying information of the variouscomponents. More specifically, tests on all three buses—one between thepower-pack and battery, another between the power-pack and outer shellhousing, and another between the power-pack and adapter—are performed,followed by verification and identification along the three busesindividually. The power-pack monitors the 1-wire buses at a minimum rateof 1 Hz for the presence of an attached outer shell housing, adapter,and/or reload.

Turning to FIG. 77, a method 1700 for testing the wires is depicted.Although any one of the wire tests can be initially performed, for thepurposes of this description, method 1700 begins with a power-pack andbattery 1-wire test at S1706. Here, a determination is made as towhether a connection between the power-pack and battery 1-wire existsand is authentic at S1708. If the connection between the power-pack andbattery 1-wire exists but is not authentic (e.g., a 1-wire orauthentication error results), use of the power-pack remains available,except for entering the firing state, a fault tone occurs, and an errorscreen is displayed at S1710. If the connection is authorized, adetermination is made at S1712 as to whether the testing is beingperformed during initialization. If so, a battery identifier (ID) isrecorded in the memory at S1714 so that the power-pack recognizes therecorded battery ID. As a result, if another battery with a differentbattery ID is used with the power-pack, an error screen is displayed andthe power-pack is unable to operate with the unidentified battery. Ifthe connection between the power-pack and battery 1-wire exists and isauthentic and the test is not performed during initialization or if theID has been recorded after detecting the initialization, the existenceof a next test is determined at S1702, and if the next test exists, thenext test is identified at S1704. If not, method 1700 ends.

If identified as being the next test to be performed, a clamshell 1-wiretest is performed at S1718. At S1720, a determination is made regardingwhether an outer shell housing is connected to the power-pack andwhether the outer shell housing is authentic at S1720. In particular, atest across the outer shell housing 1-wire bus is performed to determinewhether an outer shell housing is connected to the power-pack. If theouter shell housing is authentic, an identifier (ID) for the outer shellhousing is obtained and recorded in the memory and the outer shellhousing is marked as “used” in its memory at S1710. If there is an errordetected or authentication fails, e.g., where the outer shell housinghas previously been marked as “used,” use of the power-pack is possibleexcept for entering the firing state, a fault tone occurs, and an errorscreen is displayed at S1712. Method 1700 advances to S1702, and ifneeded, S1704.

If not already performed, an adapter and reload 1-wire test is performedat S1726. Here, a test is performed across the adapter 1-wire bus todetermine if an adapter and/or a reload is connected and whether theyare authentic at S1728. If there is an error detected or authenticationfails, a determination is made as to whether the failure is due to theadapter or reload at S1730. If the failure is due to the adapter, use ofthe power-pack is possible except for entering firing state, a faulttone occurs, and an “adapter” error screen is displayed at S1732. If thefailure is due to the reload. Additionally, use of the power-pack ispossible except for entering firing state, a fault tone occurs, and a“reload” error screen is displayed at S1734.

With reference again to FIG. 73, after the wire testing, method 1300advances to S1306, where a determination is made as to whether any ofthe initialization tests have not been performed. If so, a next test isidentified to be performed at S1308. If a number of uses remaining ofthe power-pack has not yet been verified, such operation is performed atS1330. In particular, a determination is made as to whether a firingcounter is equal to or greater than a predetermined value representing afire limit. The firing counter, stored in the memory of the power-pack,is obtained, and if the firing counter is equal to or greater than thefire limit, method 1500 is performed where the power-pack is operableexcept for entering firing state (S1502), a fault tone occurs (S1504),and a screen image communicating that no uses left is displayed (S1506).After S1330, method 1300 returns to S1306 and S1308 to identify a nexttest to be performed, if any. If no test remains to be performed, method1300 ends.

Prior to use, and in some instances, assembly, the battery of thepower-pack is preferably charged, the performance of which is controlledby charging module 1116 (FIG. 71). In an embodiment, upon connection tothe charger, charging module 1116 provides instructions to thepower-pack to release master control of a bus used to communicate withthe battery. Although master control is released, the power-packreceives the time and is capable of updating the clock during connectionto the charger. Connection with the charger may be made via electricalcontacts associated with the battery circuit board 140, communicationtherebetween may be accomplished over 1-wire bus 167 (see FIG. 70). Inan embodiment, the power-pack is not connected to the externalcommunication system and does not enter the standby mode while charging.Information is available for display. For example, information from aprevious procedure, a remaining firing count and/or procedure count,and/or remaining firing and autoclave counts in any attached adapter areavailable to be read by the user. Upon removal of the power-pack fromthe charger, the power-pack is restarted.

During assembly of the surgical device, validation module 1118 providesinstructions for performing testing to detect whether a component (e.g.,outer shell housing, adapter, or reload) being connected to thepower-pack is valid. FIG. 78 is a flow diagram of a method 1800 ofvalidating the components, in accordance with an embodiment. Althoughany one of the validation tests can be initially performed, for thepurposes of this description, outer shell housing validation with thepower-pack is performed at S1806. In response to detecting engagement ofan outer shell housing with the power-pack, the power-pack initiates atest, across the corresponding 1-wire bus, to determine whether theouter shell housing is valid at S1808. During the validation, a displayscreen indicating testing is displayed. If the outer shell housing isinvalid or unsupported, a fault tone occurs and a “clamshell error”screen is displayed at S1810. In addition to determining validity,method 1800 includes identifying whether the outer shell housing hasbeen previously used at S1812. In this regard, the memory of the outershell housing is read for data, and the data is compared to data storedin the memory of the power-pack. If the outer shell housing has beenpreviously used, method 1800 proceeds to S1810 where a fault tone issounded and an error screen is displayed on the display screen. In anembodiment, the power-pack is also inhibited from entering the firingstate.

Returning to S1808 and S1812, if a valid and unused outer shell housingis detected, the power-pack records the ID of the outer shell housing inthe memory of the power-pack and marks the outer shell housing as usedby writing such to its memory at S1814. Method 1800 then advances toS1802 and, if needed, to S1804 to identify a next test.

If not yet performed, the adapter is validated at S1816. The power-packmonitors the 1-wire bus at a minimum rate of 1 Hz for the presence of anadapter, and a “request adapter” screen is shown while waiting for theadapter, if a power-pack statistics is not already displayed on thedisplay. In response to the detection of the adapter, the power-packdetermines whether the adapter has a valid ID at S1818 and is supportedat S1820. If the adapter is unable to be identified, an error screen isdisplayed, a fault tone is sounded, and entering the firing state isinhibited at S1822. If the adapter is found to be unsupported, nofurther operation is permitted, a fault tone is sounded, and an errorscreen is displayed at S1824. If the adapter has a valid ID and issupported, the values of the two counters associated with the adapterare examined at S1826. Specifically, the power-pack reads theidentifying and counter data from the attached adapter. In an example,with respect to the counters, the power-pack reads the firing count andan assumed autoclave count stored in the memory of the adapter andcompares these values to the limits stored in the memory of thepower-pack. If the adapter is found to have no remaining firings or noremaining autoclave cycles, a screen indicating the same is displayedand entering the firing state is inhibited at S1828. Otherwise, method1800 advances to S1802, and if needed, S1804, for the identification ofa next test to be performed.

In an embodiment, the next test to be performed includes validating areload at S1830. Turning now to FIG. 79, the power-pack monitors the1-wire communication bus to the adapter to detect whether a reload isattached and the type at S1832. For example, as detailed above, a switchof the adapter is actuated upon coupling of the reload thereto,providing a detectable indication to the power-pack that a reload isattached.

As noted above, different types of reloads can be attached to theadapter. For the purposes of this description, a first type of reload isones that is not recognized as being a SULU-type reload, e.g., similarto SULU 400 (FIG. 1), or a MULU-type reload, e.g., similar to MULU 900B(FIGS. 69B1 and 69B2). This “first type” reload may be, for example,loading unit 900A (FIG. 69A), loading unit 900C (FIG. 69C), or loadingunit 900D (FIG. 69D). SULU-type reloads and MULU-type reloads areconsidered to be a “second type” of reload. SULUs and MULUs are readilyidentifiable and distinguishable by power-pack using the 1-wirecommunication system; however, for purposes of simplicity, both SULUsand MULUs are treated herein as being reloads of the second type.Further, although only two types of reloads, e.g., first types andsecond types, are detailed herein, it is understood that the power-packcan be configured to recognize any number of reload types.

If the first type of reload is detected, method 1800 advances to S1834,where the power-pack reads the memory of the reload in search of areload ID. If a reload ID is detected, the power-pack tests theencryption of the reload ID at S1836. If at S1834 or S1836 either thereload ID is not recognized or the reload does not pass encryption, nooperations are possible, a fault tone occurs, and a “reload error”screen is displayed at S1838. Otherwise, method 1800 advances to S1802,and if needed, to S1804.

Returning to S1832, if the second type of reload is detected, method1800 advances to S1850, where a scan is made to determine whether thereload is capable of providing information, e.g., via a memory (with orwithout a processor) of the reload, RFID chip, barcode, symbolic label,etc., and/or the type of reload that is connected to the adapter. If thereload is determined not to be capable of providing information, thereload is identified as a legacy reload and a “check reload” screen isdisplayed at S1852. A check of whether the reload is connected properlyis performed at S1854. If not connected properly, a fault tone occursand a “reload error” screen is displayed at S1856. If the reload isconnected properly, method 1800 returns to S1802 and S1804 (if needed)for the identification of a next test, if any.

If the reload is determined to be capable of providing informationand/or the type of reload connected to the adapter is detected at S1850,the reload is considered a smart reload and an encryption of the smartreload is tested at S1858. If the encryption of the smart reload failstesting, operation can continue, except entering the firing state, thefault tone occurs, and the “reload error” screen is displayed at S1860.Similarly, if an unknown ID of the smart reload is detected or the1-wire ID is detected by the reload switch is not property recognized,operation can continue, except entering the firing state, the fault toneoccurs, and the “reload error” screen is displayed at S1860.

If encryption of the smart reload passes testing at S1858, a detectionis made as to whether the second type of loading unit is a SULU, e.g.,SULU 400 (FIG. 1), or a MULU, e.g., MULU 900B (FIGS. 69B1 and 69B2), atS1862. If a SULU is detected, the SULU is tested to detect whether ithas been used at S1864. If it is determined to be used, the power-packcan be used, except entering firing state, a fault tone occurs, and a“reload error” screen is displayed at S1860. Otherwise, method 1800returns to S1802 and S1804, if needed.

If a MULU is detected, a firing counter of the MULU is read to determinewhether the firing counter is greater than a fire limit at S1866. If thefiring counter is greater than a fire limit, the “no uses left” screenis displayed and the power-pack can be used, except entering firingstate at S1868. If the firing counter is not greater than the fire limitat 1860, a scan is performed to detect a staple cartridge at S1870. Ifno staple cartridge is present, an “incomplete reload” screen isdisplayed at S1872. If a staple cartridge is present, method 1800advances to S1864, to determine whether the staple cartridge has beenused. Depending on the outcome at S1864, method 1800 may advance toS1860 or S1802 as described above.

Upon detection of a valid adapter with at least one use remaining and atleast one autoclave cycle remaining, the operation functions arecalibrated, instructions for which are provided by calibration module1120. The calibration process can differ depending on the particulartype of adapter attached to the power-pack.

FIG. 80 is a flow diagram of a method 2000 of calibrating thearticulation and firing functions of an adapter capable of attaching toa reload of the first type. A determination is made as to whether areload is attached to the adapter at S2002. If a reload is attached tothe adapter, calibration does not occur, an error screen is displayed,and a fault tone is sounded at S2004. If a reload is not attached to theadapter, a determination is made as to whether the software versionstored in the adapter is compatible with the software of the power-packat S2006. It will be appreciated that in another embodiment, calibrationoccurs regardless of whether a reload is attached, and hence in such anembodiment method 2000 begins from S2006. If the software version storedin the adapter is not compatible with the software of the power-pack,the power-pack updates the adapter software before calibration at S2008.At S2010, a determination is made as to whether the update issuccessful. If such update fails, firing calibration is performed butarticulation calibration is not performed and entering the firing stateis prohibited at S2012. If the software of the adapter and power-packare found to be compatible at S2006 or the software update is successfulat S2010, calibration of the articulation function and the firingfunction occurs at S2014. Calibration of the articulation functioninvolves obtaining a reference position by driving the articulationshaft left until it stops at its mechanical limit and then returning thearticulation shaft back to the center position. Calibration of thefiring function is effected by obtaining a reference position by drivingthe firing shaft proximally until it stops at its mechanical limit,followed by returning the firing shaft distally to its home position.

After performing the firing and articulation calibrations, adetermination is made as to whether the calibration has been successfulat S2016. If either the firing or articulation calibration fails atS2016, no further operation is permitted until the adapter is replacedor reconnected and calibration is properly obtained at S2018. Ifcalibration is successful, the adapter is operable in the firing stateat S2020. If a reload is subsequently detected as removed at S2022, arequest reload screen is displayed at S2024. A determination is made asto whether movement has occurred since a calibration of the adapter atS2026. If so, an articulation centered occurs at S2028. If no movementhas occurred since the last calibration at S2026, the firing rod is notmoved to a home position and articulation will not be centered at S2030.Returning to S2022, if the reload has not been removed, the adapterremains operable in firing state at S2020. Any buttons pressed duringadapter calibration are ignored. In an embodiment, calibration occursdespite the battery having an insufficient charge. In anotherembodiment, calibration occurs even when the adapter has no usesremaining.

FIG. 81 is a flow diagram of a method 2100 of calibrating an adapterconfigured to attach to a loading unit of the second type. Here,calibration module 1120 includes a feature to perform idle statecalibration, where the adapter is not in a stapling or cutting state.First, a determination is made as to whether the software of the adapteris compatible at S2102. If not, power-pack updates the adapter softwarebefore calibration at S2104. At S2106, a determination is made as towhether the update is successful. If such update fails, no furtheroperation is allowed, a fault tone occurs, and an error screen isdisplayed at S2108.

If the software of the adapter is found to be compatible at S2102 or issuccessfully updated at S2106, a determination is made as to whether ornot the adapter is idle at S2110. If the adapter is detected as in theidle state, the idle state calibration is performed at S2112. Inparticular, clamp shaft calibration is performed at S2114 by obtaining areference position by driving the clamp shaft proximally until it stopsat its mechanical limit. In response to an endstop, the clamp shaft isdriven distally to its home position. In addition to the clamp shaftcalibration, a staple shaft calibration is performed at S2116 by drivingthe staple shaft proximally until it stops at its mechanical limit. Inresponse to an endstop, the staple shaft is driven distally to its homeposition. The pressing of any buttons during idle state calibration isignored. Although the staple shaft calibration S2116 is described asbeing performed after the clamp shaft calibration S2114, it will beappreciated that the calibrations can be performed in no particularorder. If calibration is not performed successfully, no furtheroperation is possible until the adapter is removed, a fault tone occurs,and an “adapter error” screen is displayed.

Returning to S2110, if the adapter is not in the idle state, adetermination is made as to whether the adapter is in a stapling stateor a cutting state at S2118. If the adapter is in the stapling state,stapling state calibration is performed at S2120 by obtaining areference position by driving the staple shaft proximally until it stopsat its mechanical limit. The clamp and cut shaft calibration are notperformed concurrently with the stapling state calibration, in anembodiment, and any button presses during stapling calibration areignored.

If a cutting state is detected as S2118, calibration module 1120performs a cutting state calibration at S2128. The cutting statecalibration is performed by obtaining a reference position by drivingthe cut shaft proximally until it stops at its mechanical limit. Theclamp and staple shaft calibration are not performed concurrently withthe cutting state calibration, in an embodiment, and any button pressesduring stapling calibration are ignored.

A determination is made at S2122 as to whether the stapling state andcutting state calibrations have been performed successfully. If thestapling state calibration is successful, a firing sequence continuesfrom stapling at S2124. If the cutting state calibration is successful,a firing sequence continues from cutting at S2124. If either thestapling state or cutting state calibration is not performedsuccessfully, no further operation is possible until the adapter isremoved, a fault tone occurs, and an “adapter error” screen is displayedat S2126.

As described briefly above, operation is effectuated by utilizing thebuttons disposed on outer shell housing 10 (FIG. 1). Generally,operation module 1122 includes various modules to permit and inhibitvarious operations depending on the mode, status, state, and/or positionof, among other components, the outer shell housing, the adapter, andthe reload. The power-pack logs various data relating to the use and/oroperation of the power-pack, the adapter, and the reload viacommunications transmitted across the 1-wire buses. Such data includeskeystroke data relating to each of the buttons associated with thehandheld, event logging data, fault and error data, knife position data,firing data, open/close data, etc. FIG. 82 is a block diagram ofoperation module 1122 including its various modules, according to anembodiment. Operation module 1122 includes rotation module 2202,articulation module 2204, open module 2206, close module 2208, firingmodule 2210, safety module 2212, and counter module 2214.

Rotation module 2202 causes rotation of the adapter in response to inputreceived from pressing or actuating the appropriate button on surgicaldevice 100 (FIG. 1), as detailed above. Additionally, rotation ispermitted before attaching the adapter. In the event in which theadapter is not connected, the power-pack statistics screen is displayedon the display for a predetermined duration (e.g., 5 seconds) after allbuttons are released. Rotation also occurs with or without a reloadconnected, even where there is insufficient battery charge to fire,where no power-pack or battery uses are remaining, where the reload hasbeen used, or where the reload is in a clamp position. If another buttonis pressed during rotation, rotation is halted until the button isreleased. Further, if under an excess load is detected, rotation isstopped until the rotation button is released and re-depressed. Rotationis stopped in response to a detection of a motor velocity of 0 rotationsper minute (RPMs) and remains stopped until button depression isdetected again.

Articulation module 2204 articulates the reload. For example, inresponse to signals received from the appropriate button on surgicaldevice 100 (FIG. 1), the reload is articulated either left or right.Articulation is permitted where there is insufficient battery charge tofire, where no power-pack or battery uses are remaining, where thereload is connected, or where the reload has been used and/or has nouses remaining. Depression of another button during articulation causesarticulation to stop until the button is released. Articulation module2204 includes an articulation current limit defined and set by adjustingthe limit control on the motor controller circuit. The articulationcurrent limit correlates to a maximum torque the motor will output. Whena velocity threshold (e.g., of about −200 RPM±−5%) is reached orexceeded, articulation is stopped. Depression of any of the articulationbuttons prior to attachment of the adapter and the reload does not causearticulation. In an embodiment, when the reload is in the clamp orclosed position, articulation is effected at a slower rate as comparedto articulation in the open position (e.g., 200 RPM±10 RPM).

Open module 2206 controls the opening of reload, in response to apressing of the open button and determines whether opening operationcontinues or not based on various scenarios. For example, pressing theopen button before the adapter or the reload is attached is ignored.During a reload opening, the reload remains open until the open buttonis released or the reload is fully opened. Opening is permitted withinsufficient battery charge, with no power-pack or battery uses areremaining, or where the reload has been used. If another button ispressed during opening, opening is halted until the button is released.In an embodiment in which a trocar is used in conjunction with thesurgical device, the trocar extends until fully extended, in response toan input received from a pressed open button. If the trocar is unable tobe extended, no further operation is allowed, a fault tone occurs, andthe “reload error” screen is displayed.

Close module 2208 controls the closing of reload, in response to apressing of the close button and determines whether a close operationcontinues or not based on various detected or received inputs. In anembodiment, pressing the close button before the adapter or the loadingis attached is ignored. Closing is effectuated until the close button isreleased or the fully closed position is achieved, at which time a toneis caused to be sounded. A closing operation is permitted where there isinsufficient battery charge to fire, where no power-pack or battery usesare remaining, or where the reload has been used. If another button ispressed during closing, closing is halted until the button is released.A speed current limit is defined and set on the motor based on straingauge. The speed current limit correlates to a maximum torque the motorwill output. When a velocity threshold (e.g., of about −200 RPM±−5%) isreached or exceeded, the closing speed is reduced.

Firing module 2210 controls firing of staples in the reload by placingthe reload in a firing state (during which staples can be fired) or outof the firing state (during which staples cannot be fired). In anembodiment, entering the firing state is only permitted when each of thefollowing conditions is met:

-   -   the outer shell housing has been installed, detected, verified        as acceptable, and has not been used on a previous procedure;    -   the adapter has been installed, detected, verified as        acceptable, and calibrated successfully;    -   the reload has been installed, verified as acceptable, passed        encryption, can be marked as used, and has not been previously        fired; and    -   the battery level is sufficient for firing.        After the above conditions are met, and an input is detected        indicating that the safety has been pressed, the power-pack        enters the firing state and the attached the reload is marked as        used its memory. While in in the firing state, pressing the        close button advances the stapler pusher and knife to eject the        staples through tissue and cut the stapled tissue, until the        close button is released or the end stop of the reload is        detected. If an endstop is detected, releasing and pressing the        fire button again shall continue to advance the knife until the        fire button is released or an end stop is again detected. Firing        may continue upon re-actuation until forward progress is no        longer made between end stops.

When the fire button is released and the open button is pressed twice,at any point during firing, the power-pack exits the firing state andthe knife is automatically retracted to its home position. If the openbutton is pressed a single time during firing, i.e., while the firebutton is pressed, firing stops. Firing does not continue until both thefire and open buttons have been released and the fire button is pressedagain.

In the firing state, three speeds are provided: slow, normal, and fast.Rotation of adapter is inhibited in the firing state and, thus, therotation buttons do not effect rotation. Rather, in the firing state,the rotation buttons are actuatable to increase or decrease the firingspeed. The firing speed is initially set to normal. Articulation is alsoinhibited when in the firing state.

Loss of 1-wire communication between the power-pack and outer shellhousing and/or adapter, or loss of communication regarding reloadpresence, does not interrupt firing. However, such communication ischecked after firing and retraction have been completed.

If the firing state is exited before any forward progress is made,reentering firing state does not increment the power-pack firingcounter. Further, if the firing limit of the power-pack or adapter hasbeen reached during an operation, the firing state remains accessibleuntil the attached outer shell housing or adapter is removed.

If the firing state is exited before any forward progress is made,reentering firing state does not increment the power-pack firingcounter. Further, if the firing limit of the power-pack or adapter hasbeen reached during an operation, the firing state remains accessibleuntil the attached outer shell housing or adapter is removed.

During the firing state, if linear sensor data no longer returns duringa stapling sequence, stapling is interrupted, a fault tone occurs, andan “adapter error” screen is displayed. Additionally, if no movement ofthe staple shaft or the cut shaft is detected for a predetermined periodof time (e.g., 1 second), stapling or cutting stops, a fault toneoccurs, and a “reload error” screen is displayed. If an excessive loadis detected during a stapling or cutting sequence, the stapling orcutting ceases, a fault tone occurs, and a “power-pack error” screen isdisplayed. In an embodiment in which an insufficient load is detectedduring a stapling or cutting sequence, the stapling or cutting ceases, afault tone occurs, and a “power-pack error” screen is displayed.

Safety module 2212 controls entry of surgical device 100 (FIG. 1) intothe firing state. Specifically, the firing state is entered when safetymodule 2212 detects that:

-   -   an outer shell housing is installed, detected and supported;    -   an adapter is installed detected, supported, and successfully        calibrated;    -   SULU or MULU is installed, detected, supported, and passed        encryption;    -   MULU cartridge is installed and has not been fired;    -   SULU or MULU cartridge can be marked as used;    -   reload is installed and detected;    -   reload has not previously fired;    -   battery level is sufficient for firing; and    -   the outer shell housing has not been used on a previous        procedure.

In an embodiment, a safety LED is lit when the power-pack is fullyassembled and not in an error condition. When entering the firing state,a tone occurs and a “firing” screen is displayed, and the safety LEDflashes until the firing state is exited. The firing state is exitedwhen the open key is pressed, for example, twice, and a tone indicatingexiting firing mode is displayed. The safety LED is not lit if thepower-pack is unable to enter the firing state or when firing iscomplete.

Counter module 2214 maintains various counters that increment uponoccurrence of specific events or conditions to indicate when certaincomponents have reached the end of their usable lives. In particular,counter module 2214 maintains a power-pack procedure counter, apower-pack firing counter, an assumed autoclave counter for the adapter,and an adapter firing counter. These counters are in addition to the“used” markings assigned to outer shell housing and SULU, which aresingle-procedure-use components.

The power-pack procedure counter is stored in the memory of thepower-pack. The power-pack procedure counter is incremented when thefiring state is first entered after attaching a new outer shell housingto the power-pack. The power-pack procedure counter is not againincremented until the outer shell housing is removed a new outer shellhousing installed and the firing state again entered, regardless ofwhether the firing state is entered multiple times while housed in asingle outer shell housing. If the power-pack procedure counter cannotbe incremented, power-pack can operate except in firing state, a faulttone occurs, and a “power-pack error” screen is displayed.

The power-pack firing counter is stored in the memory of the power-pack.The power-pack firing counter is incremented each time the firing stateis entered except that, if the firing state is entered and no forwardprogress is made, reentering the firing state does not increment thepower-pack firing counter. If the power-pack firing counter limit hasbeen arrived at, power-pack is inhibited from entering the firing state.If the power-pack firing counter cannot be incremented, power-pack canoperate except in firing state, a fault tone occurs, and a “power-packerror” screen is displayed.

The adapter autoclave counter is stored in the memory of the adapter andis incremented when the firing state is first entered after attaching anew outer shell housing. Due to the adapter being a reusable component,the adapter has a pre-set limit on usages, and it is assumed that theadapter is autoclaved prior to each procedure. If the adapter autoclavecounter has already been incremented for a particular attached outershell housing, it will not be incremented again until the outer shellhousing is removed and replaced. If the adapter autoclave counter cannotbe incremented, power-pack can operate except in firing state, a faulttone occurs, and an “adapter error” screen is displayed.

The adapter firing counter is stored in the memory of the adapter and isincremented when entering the firing state except that, if the firingstate is entered and no forward progress is made, reentering the firingstate does not increment the adapter firing counter. If the adapterfiring counter limit has been arrived at, power-pack can operate exceptin firing state, a fault tone occurs, and a “power-pack error” screen isdisplayed.

In accordance with the present disclosure, in order to evaluateconditions that affect staple formation, such that a more intelligentstapling algorithm, may be developed, an electromechanical testingsystem may be used in place of a surgical device or stapler (e.g.,powered hand held electromechanical instrument 100). Theelectromechanical testing system may be configured to deploy (e.g.,fire) staples on ex vivo porcine stomach to measure forces and theresulting staple formation data may be collected. A sequential design ofexperiments may be utilized to assess the effects of four differentfactors, including speed of firing, tissue thickness, precompressiontime, and stapler length with respect to firing force and stapleformation.

It was discovered that the firing force was affected by the speed offiring, a length of the reload (e.g., stapler length) and the tissuethickness. It was also discovered that staple formation was affected bythe speed of firing and the tissue thickness. Finally, a correlation wasdiscovered between the force on the electromechanical testing system andthe staple formation; specifically, lower forces on theelectromechanical testing system yielded better staple formation (e.g.,fewer mis-formations, great complete formations, etc).

By slowing the speed of firing, particularly when relatively high forcesare seen within a stapling system (e.g., surgical device or stapler, orpowered hand held electromechanical instrument 100), the performance ofthe surgical device is improved It is contemplated that variations inthe software are available to optimize output based on different reloadtypes and in a variety of tissues with different characteristics (e.g.,density, thickness, compliance, etc.). The intelligent stapling systemsmay be configured to continue to utilize clinical data and enhancedevice performance, leading to improved patient outcomes, by updatingand/or modifying firing algorithms associated therewith.

With reference to FIGS. 83-88, another embodiment of an adapterassembly, according to the present disclosure, is illustrated as 500.The adapter assembly 500 is substantially similar to the adapterassembly 200 of FIGS. 1 and 20-26. Thus, only certain features of aswitch actuation mechanism 510 of the adapter assembly 500 will bedescribed in detail. The adapter assembly 500 includes a knob assembly502 and an elongate body or tube 506 extending distally from a distalportion of the knob assembly 502. The knob assembly 502 is configured toconnect to a handle housing, such as the handle housing 102 of thesurgical device 100 (FIG. 1). The elongate body 506 houses variousinternal components of the adapter assembly 500, such as the switchactuation mechanism 510, and includes a proximal portion 506 a coupledto the knob assembly 502 and a distal portion 506 b configured to coupleto a loading unit, such as the loading unit 400 (FIGS. 53 and 54).

The switch actuation mechanism 510 of the adapter assembly 500 toggles aswitch (not explicitly shown) of the adapter assembly 500 uponsuccessfully connecting the loading unit 400 to the adapter assembly500. The switch, which is similar to the switch 320 of FIG. 48 describedabove, is configured to couple to a memory of the SULU 400. The memoryof the SULU 400 is configured to store data pertaining to the SULU 400and is configured to provide the data to a controller circuit board ofthe surgical device 100 in response to the SULU 400 being coupled to thedistal portion 506 b of the elongate body 506. As described above, thesurgical device 100 is able to detect that the SULU 400 is engaged tothe distal portion 506 b of the elongate body 506 or that the SULU 400is disengaged from the distal portion 506 b of the elongate body 506 byrecognizing that the switch of the adapter assembly 500 has beentoggled.

With reference to FIGS. 84-88, the switch actuation mechanism 510 of theadapter assembly 500 includes a switch actuator 540, a distal link 550operably associated with the switch actuator 540, an actuation bar 584,and a latch 586 each of which being disposed within the elongate body506. In some embodiments, some or all of the components of the switchactuation mechanism 510 may be disposed on an outer surface of theelongate body 506 rather than inside.

The switch actuator 540 is longitudinally movable between a distalposition, as shown in FIGS. 85-88, and a proximal position (not shown).In the distal position, a proximal portion 540 a of the switch actuator540 is disassociated from the switch (not explicitly shown), and in theproximal position the proximal portion 540 a of the switch actuator 540toggles or actuates the switch (not explicitly shown). It iscontemplated that any suitable portion of the switch actuator 540 may beresponsible for toggling the switch.

The switch actuator 540 is resiliently biased toward the distal positionvia a biasing member (e.g., a coil spring not explicitly shown), similarto the spring 348 of FIG. 48 described above. As such, the switchactuator 540 is biased toward engagement with the switch. The switchactuator 540 includes a distal portion 540 b having a mating feature,such as, for example, a tab 542 extending laterally therefrom. The tab542 of the switch actuator 540 detachably lockingly engages the latch586 during loading of the loading unit 400 into the adapter assembly400, as will be described in detail below.

The distal link 550 of the switch actuation mechanism 510 is alignedwith and disposed distally of the distal portion 540 b of the switchactuator 540. The distal link 550 is longitudinally movable within andrelative to the elongate body 506 between a distal position, as shown inFIGS. 84-87, and a proximal position, as shown in FIG. 88. The distallink 550 has a proximal portion 550 a operably associated with thedistal portion 540 b of the switch actuator 540, and a distal portion540 b for interacting with a second lug 412 b of the loading unit 400during insertion of the loading unit 400 into the elongate body 406 ofthe adapter assembly 400. The switch actuation mechanism 510 includes abiasing member, such as, for example, a coil spring 548, disposedbetween the distal portion 540 b of the switch actuator 540 and theproximal portion 550 a of the distal link 550. The coil spring 548couples the switch actuator 540 and the distal link 550 together suchthat longitudinal movement of one of the switch actuator 540 or thedistal link 550 urges a corresponding motion of the other of the switchactuator 540 or the distal link 550.

The actuation bar 584 of the switch actuation mechanism 510 islongitudinally movable between a distal position, as shown in FIGS. 85and 86, and a proximal position, as shown in FIGS. 87 and 88. In thedistal position, a distal portion 584 b of the actuation bar 584 isengaged to or otherwise associated with the latch 586 or allow the latch586 to be released to release the latch 586 from the switch actuator540, and in the proximal position the distal portion 584 b of theactuation bar 584 is disengaged or disassociated from the latch 586 toallow the latch 586 to lockingly engage the switch actuator 540. Theactuation bar 584 has a projection or tab 588 extending laterally fromthe distal portion 584 b thereof. The tab 588 of the actuation bar 584is configured to contact and move the latch 586 when the actuation bar584 is moved from the proximal position toward the distal position.

The distal portion 584 b of the actuation bar 584 includes adistally-extending extension 590 for interacting with the second lug 412b of the loading unit 400 during insertion of the loading unit 400 intothe distal portion 506 b of the elongate body 506. The actuation bar 584is resiliently biased toward the distal position via a biasing member,e.g., a coil spring 592 (FIG. 84). As such, the actuation bar 584 isresiliently biased toward a state in which the tab 588 of the actuationbar 584 is engaged with the latch 586.

The latch or arm 586 of the switch actuation mechanism 510 is pivotablycoupled to an internal housing or support structure 594 disposed withinthe elongate body 506. The latch 586 is elongated and has a proximalportion 586 a associated with the switch actuator 540 and a distalportion 586 b associated with the actuation bar 584. The proximalportion 586 a of the latch 586 has a hooked configuration and includes amating feature, such as, for example, a groove 596 defined therein. Thegroove 596 is dimensioned for receipt of the tab 542 of the switchactuator 540. In embodiments, the distal portion 540 b of the switchactuator 540 may have the groove 596 rather than the tab 542, and theproximal portion 586 a of the latch 586 may have the tab 542 rather thanthe groove 596. The distal portion 586 b of the latch 586 also includesa mating feature, such as, for example, a projection 587 that defines aramped surface 589 for engaging the tab 588 of the actuation bar 584during distal movement of the actuation bar 584.

The latch 596 is pivotable relative to the support structure 594 betweena first position, as shown in FIGS. 85 and 86, and a second position, asshown in FIGS. 87 and 88. In the first position, the proximal portion586 a of the latch 586 is oriented away from and out of engagement withthe tab 542 of the switch actuator 540. The latch 586 enters and/or ismaintained in the first position when the tab 588 of the actuation bar584 is engaged with the projection 587 of the distal portion 586 b ofthe latch 586 due to the actuation bar 584 being in the distal position.

The latch 586 is resiliently biased toward the second position via abiasing member, such as, for example, a leaf spring 598 fixed to thesupport structure 594 disposed within the elongate body 506. As such,the leaf spring 598 urges the proximal portion 586 a of the latch 586into engagement with the tab 542 of the switch actuator 540. The latch586 may enter the second position, via the biasing force of the leafspring 598, when the tab 588 of the actuation bar 584 is disposed in theproximal position out of engagement with the projection 587 of thedistal portion 586 b of the latch 586.

In operation, with reference to FIG. 86, the SULU 400 is oriented suchthat the first lug 412 a thereof is aligned with the actuation bar 584of the adapter assembly 500 and the second lug 412 b thereof is alignedwith the distal link 550 of the adapter assembly 500. The SULU 400 isinserted into the distal portion 506 b of the elongate body 506 of theadapter assembly 500 to engage the first lug 412 a of the SULU 400 withthe extension 590 of the distal portion 584 b of the actuation bar 584.At this stage of loading the SULU 400 into the adapter assembly 500, theactuation bar 584 of the switch actuation mechanism 510 remains in thedistal position, in which the tab 588 of the actuation bar 584 isengaged with the projection 587 of the distal portion 586 b of the latch586, thereby maintaining the latch 586 in the first position.

Also at this stage of loading the SULU 400 into the adapter assembly500, the extension 590 of the distal portion 584 b of the actuation bar584 extends distally beyond the distal portion 550 b of the distal link550 a distance “Z.” Since the extension 590 of the distal portion 584 bof the actuation bar 584 projects distally beyond the distal portion 550b of the distal link 550, the second lug 412 b of the SULU 400 is notyet engaged with the distal portion 550 b of the distal link 550, asshown in FIG. 86.

Further insertion of the SULU 400 within the elongate body 506 of theadapter assembly 500 starts to translate the actuation bar 584 in aproximal direction, as indicated by arrow “G” in FIG. 86. Proximaltranslation of the actuation bar 584 disengages the tab 588 of thedistal portion 584 b of the actuation bar 584 from the projection 587 ofthe distal portion 586 b of the latch 586, as shown in FIG. 87, to allowthe leaf spring 598 to pivot the proximal portion 586 a of the latch 586toward the tab 542 of the switch actuator 540, in the directionindicated by arrow “H” in FIG. 87. The tab 542 of the distal portion 540b of the switch actuator 540 is received within the groove 596 of theproximal portion 586 a of the latch 586 such that the latch 586 preventsthe switch actuator 540 from moving proximally relative thereto.

Upon the actuation bar 584 translating in the proximal direction thedistance “Z,” which occurs after or concurrently with the latch 586locking with the switch actuator 542, the second lug 412 b of the SULU400 engages the distal portion 550 b of the distal link 550 of theswitch actuation mechanism 510, as shown in FIG. 87. Thus, furtherinsertion of the SULU 400 into the elongate body 506 of the adapterassembly 500 starts to translate the distal link 550 in the proximaldirection, as shown in FIG. 88. Due to the switch actuator 540 beinglocked in the distal position by the latch 586, the proximal translationof the distal link 550 does not move the switch actuator 540. Instead,the distal link 500 moves toward the switch actuator 540 to compress(e.g., load) the biasing member 548 disposed therebetween. At this stageof loading the SULU into the elongate body 506 of the adapter assembly500, the SULU 400 is not locked to the adapter assembly 500 and theswitch of the adapter assembly 500 is not toggled.

To complete the loading process, the SULU 400 is rotated relative to theelongate body 506. Rotating the SULU 400 moves the first lug 412 a ofthe SULU 400 out of engagement with the extension 590 of the actuationbar 584 to allow the distally-oriented biasing force of the biasingmember 592 (FIG. 84) of the actuation bar 584 to distally translate theactuation bar 584, which captures the first lug 412 a of the SULU 400between a distal cap 507 of the elongate body 506 and the extension 590of the actuation bar 584. In addition to locking the SULU 400 to theelongate body 506, the distal translation of the actuation bar 584 alsomoves the tab 588 of the distal portion 584 b of the actuation bar 584back into engagement with the projection 587 of the distal portion 586 bof the latch 586, whereby the latch 586 pivots, in the directionindicated by arrow “I” in FIG. 88, to release the tab 542 of the switchactuator 540 from the groove 596 of the proximal portion 586 a of thelatch 586.

Upon unlocking the switch actuator 540 from the latch 586, theproximally-oriented force of the loaded coil spring 548 is allowed toact on the switch actuator 540 to translate the switch actuator 540 inthe proximal direction away from the distal link 550, which remains inthe proximal position due to the engagement with the second lug 412 b ofthe SULU 400. As the switch actuator 540 moves into the proximalposition (not shown), the proximal portion 540 a of the switch actuator540 engages and toggles the switch of the adapter assembly 500 toindicate to the adapter assembly 500 that the SULU is successfullyattached thereto. The proximal translation of the switch actuator 540also compresses (e.g., loads) the biasing member (not shown) of theswitch actuator 540.

To selectively release the SULU 400 from the adapter assembly 500, aclinician may translate or pull a release lever 513 (FIGS. 83 and 84)disposed on the knob assembly 502 of the adapter assembly 500. Therelease lever 513 is directly coupled to the proximal portion 584 a ofthe actuation bar 584 such that proximal movement of the release lever513 causes the actuation bar 584 to move proximally. Proximal movementof the actuation bar 584 moves the distal portion 584 b of the actuationbar 584 out of engagement (or out of blocking axial alignment) with thefirst lug 412 a of the SULU 400 and the SULU 400 can be rotated.

While holding the release lever 513 in the proximal position, andconsequently the actuation bar 584, the SULU 400 may then be rotated andtranslated distally out of the elongate body 506. As the SULU 400 isremoved from the elongate body 506, the actuation bar 584 moves distallyunder the distally-oriented bias of the coil spring 592, and both thedistal link 550 and the switch actuator 540 move distally under thedistally-oriented bias of the biasing member (not shown) of the switchactuator 542, which was loaded during the proximal translation of theswitch actuator 540 while loading the SULU 400. As the switch actuator540 is urged in the distal direction, the proximal portion 540 a of theswitch actuator 540 disengages the switch to notify the adapter assembly500 that the SULU 400 is released therefrom.

It will be understood that various modifications may be made to theembodiments of the presently disclosed adapter assemblies. Therefore,the above description should not be construed as limiting, but merely asexemplifications of embodiments. Those skilled in the art will envisionother modifications within the scope and spirit of the presentdisclosure.

What is claimed is:
 1. An adapter assembly, comprising: an elongate bodyincluding a distal portion configured to couple to a surgical loadingunit; a switch actuator movable between a proximal position, in which aswitch is toggled, and a distal position; an actuation bar movablebetween a proximal position and a distal position; and a latch movablebetween a first position, in which the latch permits proximal movementof the switch actuator, and a second position, in which the latchresists proximal movement of the switch actuator, wherein the latch isconfigured to move in response to movement of the actuation bar.
 2. Theadapter assembly according to claim 1, wherein the latch is configuredto move from the first position toward the second position in responseto the actuation bar moving toward the proximal position.
 3. The adapterassembly according to claim 1, wherein the latch is configured to movefrom the second position toward the first position in response to theactuation bar moving toward the distal position.
 4. The adapter assemblyaccording to claim 1, further comprising: a distal link disposeddistally of the switch actuator; and a biasing member disposed betweenthe switch actuator and the distal link, wherein proximal movement ofthe distal link compresses the biasing member between the switchactuator and the distal link when the latch is in the second position.5. The adapter assembly according to claim 4, wherein the actuation baris configured to move the latch toward the first position to unlock theswitch actuator from the latch during movement of the actuation bartoward the distal position, such that the biasing member moves theswitch actuator toward the proximal position.
 6. The adapter assemblyaccording to claim 1, wherein the latch includes a projection extendingfrom a distal portion thereof, and the actuation bar includes a tabextending from a distal portion thereof configured to contact theprojection of the latch.
 7. The adapter assembly according to claim 1,wherein the latch has a proximal portion defining a groove therein, andwherein a distal portion of the switch actuator has a tab extendingtherefrom dimensioned for receipt in the groove of the proximal portionof the latch.
 8. The adapter assembly according to claim 1, wherein thelatch is resiliently biased toward the second position.
 9. The adapterassembly according to claim 1, wherein the latch includes a proximalportion configured to engage the switch actuator, and a distal portionconfigured to engage the actuation bar.
 10. The adapter assemblyaccording to claim 9, wherein the proximal portion of the latch has amating feature, and a distal portion of the switch actuator has a matingfeature configured to detachably matingly engage with the mating featureof the latch when the latch is in the second position and the switchactuator is in the distal position.
 11. The adapter assembly accordingto claim 10, wherein the distal portion of the latch includes aprojection, and a distal portion of the actuation bar includes aprojection such that the projection of the distal portion of theactuation bar contacts the projection of the distal portion of the latchduring movement of the actuation bar to effect pivoting of the latch.12. The adapter assembly according to claim 1, wherein movement of theactuation bar toward the distal position pivots the latch toward thefirst position to release the switch actuator from the latch.
 13. Theadapter assembly according to claim 1, further comprising a biasingmember coupled to the latch to resiliently bias the latch toward thesecond position.
 14. The adapter assembly according to claim 1, furthercomprising a release lever fixed to a proximal portion of the actuationbar to provide manual actuation of the actuation bar.
 15. The adapterassembly according to claim 1, wherein both the switch actuator and theactuation bar are resiliently biased toward their distal positions. 16.An adapter assembly, comprising: an elongate body including a proximalportion configured to couple to a handle assembly and a distal portionconfigured to couple to a surgical loading unit; a switch actuatormovable between a proximal position, in which a switch is actuated, anda distal position; a distal link disposed distally of the switchactuator and being operably coupled thereto; an actuation bar movablebetween a proximal position and a distal position; and a latch movablebetween a first position, in which proximal movement of the switchactuator is permitted, and a second position, in which the latch resistsproximal movement of the switch actuator, wherein the latch isconfigured to move from the second position toward the first position inresponse to the actuation bar moving toward the distal position to allowthe switch actuator to move relative to the distal link and toward theproximal position.
 17. The adapter assembly according to claim 16,further comprising a biasing member disposed between the switch actuatorand the distal link, wherein proximal movement of the distal linkcompresses the biasing member between the switch actuator and the distallink when the latch is in the second position.
 18. The adapter assemblyaccording to claim 17, wherein the actuation bar is configured to movethe latch toward the first position to unlock the switch actuator fromthe latch during movement of the actuation bar toward the distalposition, such that the biasing member moves the switch actuatorrelative to the distal link and toward the proximal position.
 19. Theadapter assembly according to claim 16, wherein the latch includes aprojection extending from a distal portion thereof, and the actuationbar includes a tab extending from a distal portion thereof configured tocontact the projection of the latch to pivot the latch toward the firstposition upon the actuation bar moving toward the distal position. 20.The adapter assembly according to claim 16, wherein the latch has aproximal portion defining a groove therein, and wherein a distal portionof the switch actuator has a tab extending therefrom dimensioned forreceipt in the groove of the proximal portion of the latch.